Case Study: Churchill,

Stoke-on-Trent

Churchill

2 MWp (5,195 panel) installation

A long-standing name in British manufacturing

Churchill is a long-established ceramics manufacturer based in Stoke-on-Trent, with origins dating back to 1795. Supplying ceramic tableware to the hospitality and retail sectors worldwide, the business combines historic craftsmanship with modern manufacturing processes. As the business has expanded, Churchill has made reducing energy use and improving efficiency a priority across its manufacturing operations.

As an energy-intensive manufacturer, Churchill wanted to reduce its reliance on grid electricity while supporting its wider sustainability commitments. Solar PV was identified as a practical way to generate electricity on site, cut carbon emissions and reduce exposure to fluctuating energy prices. With buildings added and adapted over many decades, the project needed a flexible approach from the very beginning.

A rooftop with generations in the making

Churchill’s Stoke-on-Trent facility is made up of numerous buildings constructed at different times, each with its own roof type, height and layout. The site includes a mix of older factory roofs and newer industrial units, as well as varied orientations and roof conditions.

Some areas required repairs before solar installation could begin, while others contained roof lights, vents and services that restricted usable space. As a result, each roof had to be surveyed and designed as a separate element, increasing the technical complexity of the installation.

Not your everyday install

One of the main challenges was limited grid capacity in the area. Churchill was among the last businesses locally to secure grid approval, and the solar PV system had to operate with no electricity exported back to the grid. The system was carefully designed to minimise lost commercial benefit due to the grid’s export limitation.

The scale and layout of the site also made installation more complex. Solar panels
needed to be installed across multiple roofs and connected into more than one
transformer, while work had to be phased to minimise disruption to day-to-day
manufacturing. In addition, the project took place during a period of global supply
chain disruption caused by COVID-19, making the sourcing of equipment more
challenging.

Making it work, roof by roof

Mypower designed a site-specific solar PV system that reflected the layout of the buildings, electrical infrastructure and day-to-day manufacturing demands. Installation was completed in several phases, allowing work to be carefully
coordinated around roof repairs, factory operations and electrical constraints.

A specialist control solution was installed to manage the system safely and ensure compliance with grid restrictions. Throughout the project, Mypower worked closely with Churchill’s internal teams to maintain clear communication, ensure
safety on site and deliver the project with minimal disruption.

Taking power in the right direction

Across four separate installations, Mypower delivered a premium SolarEdge system with a total capacity of 2,025 kWp. The system generates approximately 1,666,367 kWh of clean electricity each year, supplying a significant proportion of Churchill’s on-site energy demand.

By producing renewable electricity at source, the system helps Churchill avoid around 345.1 tonnes of CO2 emissions annually, making a meaningful contribution to the company’s sustainability targets.

From a financial perspective, the solar PV system delivers strong long-term value, with the cost of solar energy generated on site offering a 72% saving compared to purchasing electricity from the grid. This reduces reliance on grid electricity and helps shield the business from ongoing energy price fluctuations.

Despite the complexity of the site and the wider challenges around grid capacity and supply chains, the Churchill solar project was delivered successfully. The installation demonstrates how even large, mixed-use manufacturing sites can benefit from solar energy with the right design and delivery approach. Mypower is proud to have partnered with Churchill on this project and to support their transition towards a more sustainable future.

“Mypower demonstrated a strong understanding of the challenges presented by our site and took a flexible, collaborative approach throughout the project. The phased installation allowed us to continue operations while progressing towards our sustainability goals. We’re pleased with both the process and the long-term benefits the solar installation will deliver.”

Dave Plant, Production Director at Churchill.

“This was a complex site with multiple roof types,electrical constraints and grid limitations. By taking a phased and flexible approach, we were able to deliver a solar solution that works effectively for the site and supports Churchill’s sustainability goals. I was proud to project manage this complex install, as I know seeing first hand the benefits the total install will bring to the site”

Tom Sivil, Mypower's Project Manager.

Key facts and predictions

2,025 kWp (5,194 panels) installed.
1,666,367 kWh units of energy produced per annum.
£298,076 projected first year income and savings.
20% projected first year return on capital invested, before capital allowance benefits.
5.46p/kWh - the equivalent forward purchase price of 38 million units of electricity over 25 years including
estimated operating & maintenance costs.
4.99 years - system payback before finance, tax and capital allowance and grant benefit.
£12,072,482 - a 25-year income and savings after indexation.
71% saving from solar PV electricity compared to grid supplied electricity at 19p/kWh.
345.1 tonnes of CO2 emissions avoided per annum.