Project overview
Hybrid Asset Solutions was appointed to design and propose a rooftop solar PV system for a commercial site in Ellesmere Port, with the aim of reducing the client’s reliance on grid electricity and improving long-term energy cost certainty.
The proposed system consisted of a 64.8 kWp rooftop solar PV array, designed across eight separate roof groups to suit the building’s existing roof layout. Based on the site’s energy profile and roof conditions, the system was modelled to generate 45,737 kWh of electricity per year, offsetting approximately 53% of the site’s annual electricity consumption.
With a total system cost of £71,944 excluding VAT, the project was forecast to deliver £7,815 of first-year electricity bill savings, with a payback period of 7 years and 8 months. Over a 20-year period, the system was projected to generate £211,688 in net lifetime savings after capital cost.
Challenges
The client’s site had an annual electricity consumption of approximately 86,000 kWh, with utility bills projected at around £22,000 per year. With electricity costs assumed to rise by 7% annually, the business needed a practical way to reduce exposure to future energy price increases.
The roof itself presented several design challenges. The building had a multi-pitched corrugated metal roof, requiring the solar PV system to be split across eight separate panel groups. These roof sections varied significantly in orientation, with azimuths ranging from 55° to 239°, and also included shallow roof pitches.
Shading was another important consideration. The site had a notable shading loss factor of 27.5%, creating a 0.725 shade factor within the system modelling. This meant the solar design had to work carefully around the constraints of the existing building, rather than relying on a simple, single-orientation roof layout.
The client required a system that could deliver meaningful bill reduction, a sensible commercial payback, and strong long-term performance without requiring major structural changes to the existing roof.
Solution
Hybrid Asset Solutions carried out a detailed site assessment and produced MCS-compliant performance modelling to assess the viability of rooftop solar PV for the site.
The proposed solution was a 64.8 kWp solar PV system using 144 JA Solar JAM54D41-450/LB n-type bifacial double-glass modules. These high-performance 450 W panels were selected for their durability, efficiency and long-term output, supported by a 25-year product warranty and a 30-year linear performance warranty.
The system design also included one Solis S6-GC80K 80 kW three-phase inverter, providing the power conversion capacity required for a commercial-scale installation. For mounting, Hybrid specified the Renusol MS+P system, designed for trapezoidal sheet metal roofs and supported by MCS012 certification and a 10-year system warranty.
To support safe operation and maintenance, the proposal included eight IMO IP66 enclosed DC isolators, allowing string disconnection where required.
A key part of the design was the eight-group panel layout. Rather than treating the roof as a limitation, Hybrid designed the array around the building’s existing geometry to maximise available generation despite shading and orientation constraints.
The financial modelling also assessed payback, projected lifetime savings, on-site consumption, export potential and Smart Export Guarantee revenue from surplus electricity exported at £0.07 per kWh.
Outcome
The proposed solar PV system was modelled to generate 45,737 kWh of electricity per year, offsetting 53% of the site’s annual consumption. Of this, 25,457 kWh was expected to be consumed directly on site each year, helping the client reduce imported electricity from the grid.
From a commercial perspective, the system offered a strong long-term return. The total system price was £71,944 excluding VAT, with no deposit required. First-year electricity bill savings were estimated at £7,815, with total utility bill savings of £283,632 over a 20-year horizon.
After deducting the capital cost of the system, the net lifetime saving was projected at £211,688, with a payback period of 7 years and 8 months. The modelled PV-only grid self-sufficiency figure was 29.5%, giving the client a meaningful reduction in reliance on imported power.
The environmental benefits were also significant. The system was projected to avoid approximately 12 tonnes of CO₂ emissions per year. Over the system lifetime, this was estimated to be equivalent to planting 2,226 trees, avoiding 346,222 km of car travel, or preventing the emissions associated with 248 long-haul flights.
Conclusion
This project demonstrates how a well-designed rooftop solar PV system can deliver meaningful commercial and environmental benefits, even on a complex roof with multiple orientations and notable shading.
By combining detailed site assessment, MCS-compliant modelling, high-quality solar components and careful financial forecasting, Hybrid Asset Solutions provided the client with a practical, data-led proposal for reducing energy costs and improving long-term sustainability.
The proposed 64.8 kWp system gave the client a clear route to lowering electricity bills, reducing grid dependence and generating long-term savings, all while working within the constraints of the existing building.
