S & L United Storage Systems wanted to reduce energy costs and improve the long term efficiency of its manufacturing facility in Haverhill, Suffolk. The business operates from a busy production workshop and factory environment where reliable power is essential to day to day operations. With rising energy costs and increasing focus on sustainability, the client was exploring the installation of a commercial solar PV system to offset electricity consumption and improve operational efficiency.
Before approaching JR Revell, the client had received advice from another contractor whose proposal focused primarily on maximising the number of solar panels installed on the available roof space. However, no detailed review had been undertaken to assess the building’s energy usage, projected savings or expected return on investment. The client wanted confidence that any renewable energy investment would deliver genuine commercial value rather than simply maximise generation capacity.
JR Revell was brought in at the design stage to take a more strategic approach. Working closely with the client, the team reviewed annual electricity consumption data, analysed operational energy demands and carried out detailed generation calculations before developing a tailored system design. Rather than filling the roof with panels, the focus was on designing a solution aligned with the building’s actual energy requirements and long term financial objectives.
The project presented several technical and logistical challenges. The facility remained fully operational throughout the works, with live manufacturing activities, occupied offices and a customer facing trade counter operating beneath the installation area. The existing roof structure consisted of ageing corrugated cement sheets containing fragile areas and rooflights, requiring careful planning and risk management before work could commence.
Early preparation was critical to the project’s success. Asbestos surveys were completed prior to installation, while internal fall arrest netting, temporary edge protection and a fully scaffolded access system with loading platform were installed to create a safe working environment. Particular attention was given to roof penetrations, material handling and weather conditions to minimise risk while protecting the integrity of the existing building.
A key decision during the design phase was selecting a system that delivered the strongest return on investment rather than the largest generation capacity. The mounting system, panel layout and inverter location were carefully assessed to balance performance, maintenance access and long term reliability. This design led approach ensured the client invested in the right system for their business, avoiding unnecessary expenditure on oversized generation or battery storage that would have extended the payback period.
Installation works were carefully coordinated with the client’s operational team to minimise disruption. Any required electrical shutdowns were completed outside normal working hours, while material deliveries and lifting operations were planned around daily site activities. Close communication with site management ensured works progressed safely and efficiently throughout the programme.
JR Revell delivered a complete 49.2 kWp roof mounted solar PV installation, including design, installation, testing and commissioning. The completed system is forecast to generate approximately 52% of the facility’s annual electricity demand. Based on current consumption data, the installation is expected to achieve a payback period of approximately five years and deliver projected energy cost savings of more than £230,000 over a twenty year period.
Beyond the financial benefits, the project provides the client with greater energy resilience, reduced reliance on grid supplied electricity and a more sustainable operating model. The system is supported by an ongoing annual maintenance programme delivered by JR Revell’s renewable energy team, ensuring continued performance and long term value.
This project demonstrates JR Revell’s approach to renewable energy delivery. Rather than recommending the largest possible installation, we designed a system around the client’s actual energy requirements, operational demands and commercial objectives. By combining detailed energy analysis, practical engineering expertise and safe delivery within a live manufacturing environment, we provided a solution that delivers measurable long term value.
The project also strengthened an already established relationship between JR Revell and S & L United Storage Systems. Following the successful completion of the solar PV installation, JR Revell has continued to support the business with electrical installations, modifications and fire alarm works across its facilities, as well as collaborating on wider commercial projects. It is a partnership built on trust, responsiveness and a shared commitment to doing things properly from day one.
Scope of Works
• Full commercial solar PV design and energy consumption analysis
• Solar generation modelling and return on investment calculations
• Roof condition assessment and installation planning
• Asbestos survey coordination
• Temporary access, scaffolding and fall protection coordination
• 49.2 kWp roof mounted solar PV installation
• Trina Solar PV module installation
• Solar inverter installation
• Renusol mounting system installation
• AC and DC cabling installation
• Generation meter installation
• Electrical testing and commissioning
• MCS compliant certification
• Performance monitoring setup
• Annual maintenance and servicing agreement
Key Manufacturers
• Trina Solar PV Modules
• Solis Inverters
• Renusol Mounting System
• Unistrut Support Systems
• Legrand Cable Management Systems
