With energy-intensive cooling systems running around the clock, NewCold Wakefield faced both rising energy costs and increasing pressure to meet sustainability targets.
In partnership with Harvest Green Developments, the site implemented a 1MW rooftop solar PV system alongside their site in Corby, generating 851.76MWh annually and contributing to long-term carbon reduction. The installation integrates renewable energy without disrupting critical operations, while creating a model for other facilities in the frozen storage and distribution industry.
Technical and operational challenges overcome
The Wakefield warehouse presented significant challenges due to the roof’s height and fire classification. At 43 metres, the roof required a fully ballasted mounting system to avoid mechanical penetration, protecting both the roof structure and the fire integrity rating. To comply with insurer requirements, a temporary staircase and 600 linear metres of handrails were installed, ensuring safe access for both the installation team and ongoing maintenance. Planning permissions for the solar array and safety infrastructure were managed entirely by Harvest Green Developments.
The solar system uses 1,640 Canadian Solar CS6.1-72TB-610 Tier 1 modules paired with Solaredge inverters and 820 S1400 optimisers. The Enstall Panelclaw mounting system provides durability and long-term reliability, while Solis Cloud and Juggle Energy monitoring ensure that every module, string, and inverter is tracked for performance and efficiency. Over 6,500 MC4 connectors were fully verified to eliminate cross-compatibility issues, a critical step for large-scale installations where warranty protection and system reliability are paramount.
Clean energy generation and operational benefits
The rooftop solar array generates enough electricity to cover approximately 4-5% of the site’s annual energy consumption, with all output used for self-consumption. This not only reduces reliance on the national grid but also provides a stable, predictable energy source to support critical cold storage operations.
The system’s design ensures a typical payback period of 3½–4 years, with ongoing monitoring, maintenance, and rapid response services provided under Harvest Green Developments’ O&M contract. The proactive maintenance approach minimises downtime and ensures that operations, which handle over 400 lorries daily, are never impacted. The client also benefits from a spares provision for modules, MC4 connectors, and inverters, allowing any issues to be resolved swiftly.
Industry impact and replicable solutions
NewCold Wakefield sets a benchmark for renewable energy integration in the frozen storage and logistics sector. For other businesses in the industry, rooftop solar provides a clear path to cost reduction and sustainability. Facilities with high energy demand, large roof areas, or limited ground space can adopt similar solutions, and Harvest Green Developments has the expertise to manage the planning, installation, and compliance requirements unique to this sector.
The Wakefield install also highlights the potential to combine solar with other technologies, including battery storage and wind solutions, offering additional resilience and energy independence. For companies operating multiple sites, the approach can be scaled to match operational size and energy profiles, helping businesses meet their carbon reduction targets.
Collaborating for a greener cold storage sector
Harvest Green Developments works with other cold storage operators, food distributors, and logistics companies to provide tailored solar solutions that reduce costs, mitigate energy price exposure, and create long-term sustainability benefits. This project also illustrates the importance of planning for roof safety, insurance compliance, and ongoing monitoring, which are critical considerations in the industry.
Looking ahead: Future phases and expansion
With the initial 1MW array successfully energised, NewCold Wakefield is planning further phases to increase generation capacity, potentially integrating up to 4MW additional solar and exploring battery storage and wind solutions. These developments will further support the company’s green targets and reduce operational costs. The approach provides a clear roadmap for other sites in the sector to follow, demonstrating the operational and financial advantages of investing in renewable energy.
Ready to reduce costs and carbon emissions at your facility?
Harvest Green Developments specialises in designing and delivering renewable energy solutions for industrial operations with high energy demand. From solar PV to hybrid systems and battery storage, we can provide end-to-end support – from planning and compliance to installation and ongoing O&M services – helping your business save money and achieve its sustainability goals.
