The UK’s first commercial solar array using space-saving technology more commonly employed in domestic settings has been switched on by Numatic International, maker of the iconic Henry vacuum, to address the cost of energy crisis.
Designed to maximise power and minimise visual impact, the £1m micro-solar-park is seen as providing a blueprint for other manufacturers and commercial operations to adopt where limited land space is available.
Supplying clean power directly into Numatic’s energy intensive plastic moulding operations, the 5-acre site – installed by SunGift Solar – uses groundbreaking AIKO All-Back-Contact (ABC) cells paired with Sigenergy’s hybrid inverters. This combination produces over 7% more kWh per panel than conventional ground mounted solar PV arrays.
The solution allows Numatic International to generate up to 1.73 MWp in a space that would only previously have been capable of producing 1.6 MWp, and means that payback could be achieved in under five years – a period that could be halved if current high energy prices persist.
Meeting 20% of Numatic International’s annual on-site energy demand – rising as high as 100% on some days – the array of 2,672 panels enhances energy independence and long-term energy security.
Stephen George, Regulatory Affairs and Sustainability Manager at Numatic International, said: “By investing in cutting-edge solar technology, we’re reducing our environmental footprint at the same time as protecting our manufacturing operations from rapidly rising energy costs.
“Part of our ‘Operation Cleansweep’ sustainability goals, the new micro-solar-park shows what can be achieved when you reimagine how you approach small spaces. It helps us on our journey as a responsible manufacturer and accelerates our progress towards achieving Net Zero by 2035. As a result, we will be able to make the equivalent of 500,000 Henrys a year from sunshine while cutting our CO₂ emissions by 266.91 tonnes a year!”
Steve Whitlock, Finance Director at Numatic International, added: “In the current environment, every business of every size needs to consider how it’s going to secure its energy requirements in the future. This investment represents a step forward in our ability to meet our own energy needs, providing a strong return on capital compared to other investments that we may have made.”
Gabriel Wondrausch, Director at SunGift Solar, said: “Originally earmarked as a site for new manufacturing units, we calculated that by using highly efficient commercial versions of solar panels normally only used on domestic properties, we could transform a relatively small parcel of land into a hugely valuable solar asset for Numatic, capable of delivering a fifth of its annual energy needs.
“Providing a blueprint for other high-energy-use manufacturers to follow, the technology shows how small parcels of land adjoining factories or businesses can be converted into direct-feed solar power generation centres.”
The dramatic uplift in energy per panel is made possible through the use of AIKO’s ABC cells which, unlike standard utility solar panels, have their electrical contacts on the back of the unit. This creates a sleek, uninterrupted, all-black surface, free from busbars, enhancing the aesthetics of the site.
Eliminating shading on the front of the PV cells, more sunlight can be absorbed and converted into electricity, aided further by partial shading optimisation, micro-crack resistance, low degradation rates, and enhanced temperature coefficients. Together with Sigenergy’s intelligent AI-driven energy management solution, this optimises power flow and reduces power loss even on cloudy days.
Complex by its nature, the engineering challenge required SunGift Solar to connect power generated from the array into the existing electrical infrastructure, providing on-demand power that reduces the manufacturer’s reliance on the grid.
Combined with Sigenergy’s hybrid inverters, which enable a two-way energy flow, Numatic can now export surplus energy to the grid and import energy when needed.
The system is also future-proofed, with the capability of adding battery storage in phase two of the project thanks to Sigenergy’s 110kW HYA on-grid hybrid inverters, which include DC battery ports. This will enable Numatic to reduce peak demand charges and increase the proportion of energy used directly from the solar array.
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