Focused on maximising space and operational efficiency, the company operates highly automated warehouses that demand significant energy for cooling and storage. Partnering with Harvest Green Developments, NewCold Corby installed a 1MW rooftop solar PV system to reduce energy costs and support its ongoing sustainability goals.
The project, energised in April 2025, shows how industrial-scale operations can integrate renewable energy without disrupting day-to-day business. Despite challenges associated with high roof heights, fire rating requirements, and insurer compliance, the system was designed to optimise safety and efficiency while maintaining the integrity of the building’s roof structure.
Engineering solutions for a high-risk environment
NewCold Corby presented unique technical challenges. The 43-metre-high roof required a fully ballasted mounting solution to avoid mechanical penetration and maintain fire safety compliance. Harvest Green Developments collaborated with insurers and engineering partners to mitigate risks, ensuring the solar installation met all fire and structural standards. Temporary and permanent safety structures, including ballasted handrails and roof access staircases, were installed to support both construction and ongoing maintenance.
The system comprises 1,640 Canadian Solar CS6.1-72TB-610 modules paired with Solaredge inverters and optimisers, mounted with Enstall’s Panelclaw system. Juggle Energy monitoring provides module-level and holistic oversight, ensuring maximum efficiency and transparency. Over 6,500 MC4 connectors were fully verified for compatibility, preventing any risk of warranty voiding or performance issues.
Clean energy, cost savings, and operational efficiency
The installation generates 851.76MWh annually, accounting for 4-5% of NewCold Corby’s current energy demand. All energy is consumed onsite, supporting critical cold storage operations, with future expansions planned to increase solar capacity and introduce battery storage.
Financially, the project is projected to achieve a payback within 3½–4 years, with the system designed for long-term reliability. By producing energy onsite, NewCold reduces reliance on the national grid and mitigates peak electricity costs – an important consideration for a facility handling over 400 lorry movements per day.
Partnership and project delivery at scale
The success of the NewCold Corby installation reflects close collaboration between Harvest Green Developments, NewCold’s site and head office teams, and engineering partners. From tender to energisation, every stage was carefully managed to minimise operational disruption and comply with insurance, fire, and planning requirements. The installation also establishes a foundation for future renewable energy projects, including additional solar PV, battery storage, and potentially wind solutions.
Looking ahead: Expanding renewable energy at NewCold
NewCold Corby’s solar installation highlights how even high-demand, specialised industrial sites can reduce costs and enhance sustainability. With ongoing monitoring, maintenance, and future expansion opportunities, the project sets a benchmark for integrating renewable energy into cold storage operations safely and effectively.
Ready to reduce energy costs and carbon emissions?
If NewCold Corby’s solar journey inspires your business, Harvest Green Developments can deliver tailored commercial solar solutions, helping high-energy operations cut costs, boost sustainability credentials, and plan for future renewable energy expansion.
