Project Summary
Client: North West Logistics Ltd
System: 350kWp commercial solar PV with grid export
Completion: Summer 2024
Annual Savings: £68,000
CO2 Reduction: 62 tonnes per year
The Challenge
North West Logistics operates a substantial 12,000 square metre distribution warehouse in Trafford Park, Manchester's premier industrial estate. The facility serves as a regional hub for goods being distributed across the North West, with daily operations including HGV deliveries, automated picking and packing systems, refrigerated storage areas, and substantial office space. The business had identified energy costs as their second-largest operational expense after staffing, with annual electricity consumption of approximately 1.4 million kWh costing over £350,000 per year.
Beyond cost reduction, the business faced increasing pressure from major retail customers to demonstrate progress on Scope 2 emissions reduction. Several key contracts now include sustainability requirements, with regular reporting against carbon reduction targets becoming a standard contractual obligation. The board wanted a solar installation that would deliver both meaningful financial returns and substantial sustainability impact, supporting their continued growth in the increasingly ESG-conscious retail logistics market.
Our Solution
Our commercial team conducted a comprehensive feasibility assessment, including detailed analysis of half-hourly consumption data, structural roof assessment, and shading studies. We identified that the warehouse's substantial flat roof could comfortably accommodate a 350 kWp system using 875 high-efficiency 400W panels arranged in an east-west ballasted configuration. This layout maximised the use of available roof space while providing optimal generation across the working day.
The east-west configuration was particularly important for this application. By spreading generation across morning and afternoon rather than concentrating it at midday, we improved alignment with the warehouse's daily demand profile, increasing self-consumption to approximately 85% — well above the 60-70% typical for south-facing systems on similar buildings.
For the inverter system, we specified Huawei central inverters with comprehensive monitoring at panel-level optimiser detail. This provides the operations team with detailed visibility of system performance and enables rapid identification of any issues. The DC infrastructure was designed for future expansion, allowing additional capacity to be added if the business grows.
Implementation
The installation was completed over six weeks in summer 2024, with our project management team coordinating closely with the warehouse operations team to minimise disruption to business activities. Most installation work was scheduled outside peak operational hours, with weekend working used for any activities that required temporary access restrictions.
Significant project elements included structural reinforcement of three sections of the roof to accommodate the additional load, installation of ballasted mounting systems across the entire roof area, electrical infrastructure including new switchgear and a dedicated grid connection cabinet, and integration with the existing building management system for combined energy monitoring.
The grid connection process required careful coordination with Electricity North West. Following submission of our G99 application, the connection was approved within ten weeks, with witness testing conducted by ENW engineers as part of the commissioning process. The export connection allows up to 200 kW of surplus generation to be exported to the grid under the Smart Export Guarantee.
Results and Performance
The system commenced operation in July 2024 and has performed exactly as predicted in its first six months of operation. First-year generation is projected at approximately 285,000 kWh, displacing electricity costs of approximately £68,000 (after accounting for SEG export revenues). Combined with capital allowances under the Annual Investment Allowance, the post-tax payback period is just under five years.
Beyond the direct financial benefits, the installation has supported the business's broader sustainability strategy. Annual CO2 emissions have been reduced by approximately 62 tonnes, contributing to a 35% reduction in the business's Scope 2 emissions. This has supported renewal of several key customer contracts and contributed positively to the business's recent ISO 14001 environmental management certification.
Client Feedback
"Working with Nova Volt has been an outstanding experience from start to finish. They understood our operational requirements, delivered on time and on budget, and the system performance has exceeded expectations. The financial returns are substantial, but equally important has been the contribution to our sustainability credentials with key customers. We're now planning a second phase to add battery storage and EV charging." — Operations Director, North West Logistics Ltd
