The Complete Guide to Factory Solar Feasibility

Before installing a large commercial solar PV system, a factory should assess its electricity demand, roof suitability, wider electrical infrastructure, grid connection, planning requirements, fire safety considerations and the proposed installer.

A proper solar feasibility assessment brings these factors together before the final system is designed. For manufacturers with substantial daytime electricity use and suitable roof space, solar can present a strong commercial opportunity, but the right system depends on the individual site and how it operates.

Start with the factory’s electricity demand

A commercial solar PV system should be designed around how the factory actually uses electricity, not simply how many panels can fit on the roof.

Understanding when electricity is consumed helps determine an appropriate system size and how much generated power could be used on site. Actual generation, savings and payback will depend on the site’s energy use, system design, tariffs, export assumptions, finance route and operating profile.

This is particularly important when considering commercial solar PV systems for energy intensive manufacturing sites.

Assess the roof structure and condition

Large factory and warehouse roofs can provide significant space for solar, but available area alone does not determine feasibility.

Roof condition, structure, usable space and practical installation constraints all need to be understood before committing to a system design.

This can be particularly important on older industrial buildings. At Four Seasons Fuel in Coneyhurst, DW Energy installed a 106.9 kWp commercial solar PV system using 264 panels across office and fragile warehouse roofs, a handy example of why an industrial solar installation needs to be designed around the building rather than treated as a standard rooftop product.

Check the grid connection and electrical infrastructure

Commercial solar PV is part of the site’s wider electrical infrastructure, so the existing electrical installation and grid conditions need to be considered as part of feasibility.

The process may include survey and feasibility work, system design, planning and DNO work where required, followed by installation, commissioning and ongoing monitoring or maintenance according to the agreed scope.

Identifying electrical or grid constraints early provides a much clearer basis for deciding what can realistically be installed.

Consider planning, fire safety and factory operations

Planning requirements and other site-specific constraints should be identified before the installation programme is agreed.

Fire safety should also form part of the wider system and product assessment. Product choice can affect factors such as fire performance, warranty protection and long-term output, so these points should be supported by evidence for the equipment actually being specified rather than broad product claims.

Carry out due diligence on the installer

For a factory, installer selection should go beyond comparing panel specifications and headline prices - look for evidence of relevant commercial projects, current accreditations and the ability to understand the site’s wider electrical infrastructure. DW Energy has operated since 2011 and combines renewable energy installation with established electrical capability.

Our current accreditations and certifications include MCS, NICEIC, ECA, RECC consumer-code credentials and Constructionline, each relevant to different aspects of renewable installation, electrical competence, consumer protection and commercial procurement.

A prospective installer should also be able to explain clearly what happens from feasibility and design through to installation, commissioning and ongoing support.

Is your factory suitable for commercial solar?

For many manufacturers, meaningful daytime electricity demand and large roof areas can create a strong case for solar. But factory solar power should always begin with the site itself.

A feasibility assessment should establish whether the building, energy demand, electrical infrastructure and operational requirements support the proposed installation, before savings or payback assumptions become the basis for an investment decision.

If you are considering solar for a manufacturing site, book a consultation with DW Energy to discuss the commercial case for solar and storage at your factory.