Introduction
VDL Steelweld UK is a global manufacturing company with operations in Warwick. In 2019, the business began exploring renewable energy to cut costs, secure clean power and strengthen its environmental strategy. After a competitive search for suppliers, VDL Steelweld UK chose to work with us to install solar panels and EV chargers that would help futureproof their operations.
Project Goals
The company wanted to lower electricity costs, reduce reliance on the grid and demonstrate its commitment to sustainability. With funding support available, the leadership team saw an opportunity to combine solar energy with on-site EV charger installation to support their transition to electric vehicles.
The Commercial Solar Panels Installed
The installation included 100 Trina 500W solar panels, producing a total capacity of 50kWp. To expand the benefits of renewable energy, we also installed four Zappi EV chargers at the Warwick site. This addition allows staff and visitors to charge electric vehicles directly from the clean energy generated.
Timeline and Process
The first enquiry came in August 2019. Progress was slowed by funding delays and a back-and-forth quotation process as the company compared multiple providers. The grid application was also more complex than usual due to the site being split across two MPANs. Despite these challenges, the system was successfully installed in October 2022. From start to finish, the project took 26 months.
Project Results
Since installation, the solar system has generated 127.3MWh of renewable electricity, averaging 40MWh annually. The Warwick site now benefits from lower running costs and the added convenience of on-site EV charging stations powered by solar energy.
Environmental & Financial Benefits
The project has already saved 25,099 kilograms of CO₂ emissions, the equivalent of planting 1,518 trees. With a projected payback period of 8.8 years, the system is delivering both financial security and environmental impact. The addition of EV chargers ensures the business is ready to support a growing fleet of electric vehicles.
Key Performance Highlights
- 50kWp solar capacity
- 100 Trina 500W solar panels installed
- Four Zappi EV chargers installed
- 127.3MWh generated since 2022, averaging 40MWh annually
- 25,099 kg of CO₂ emissions saved
- Equivalent to 1,518 trees planted
- Projected payback in 8.8 years
Conclusion & Takeaways
VDL Steelweld UK has transformed its Warwick site with a commercial solar system and on-site EV charger installation. Despite challenges with funding and grid applications, the project has delivered strong results, reducing costs and supporting sustainable transport. This case study demonstrates how combining solar power with EV charging creates long-term value for forward-thinking manufacturers.
