Case Study: TCL Packaging, Telford

TCL Packaging Ltd

529.20 kWp (1176 panel) installation

Completing the Sustainability Strategy

Located in Telford, TCL Packaging produces flexible packaging films in accordance with ISO 14001 standards. They have intergrated a smart building management system, variable speed drives, LED lighting, and better air conditioning into the company’s modern facilities.
To meet its sustainability goals, improve supply chain recognition, and reduce risks from energy price unpredictability, TCL Packaging approached Mypower to install a commercial rooftop solar PV system.
Mypower installed a 529.2 kWp rooftop solar system with 1,176 Trina Vertex S+ 450W panels. The system, started operating at the end of February, and is expected to produce 490,280 kWh of renewable electricity annually.

Environmental Challenges through SolarEdge Technology

The selection of inverter technology for the TCL Packaging project was guided by two primary requirements: stringent safety standards and robust environmental resilience.
Due to the facility’s internal printing and film-conversion processes, algae accumulation on the rooftop occurs at an accelerated rate, resulting in significant performance losses with standard string inverters. To address this, Mypower installed four 100 kW SolarEdge inverters paired with 591 S1000 Optimisers. This panel-level optimisation prevents algae buildup in one area from reducing the output of adjacent panels and enables detailed monitoring, allowing TCL Packaging to efficiently schedule targeted roof-cleaning maintenance.
Besides performance, both the landlord and insurers required SolarEdge technology. The system has advanced fire-safety features (SafeDC™) and rapid DC shutdown, which lower DC voltage to a safe level in the event of a problem or grid outage.

Seamless Integration and Management

The system uses a SolarEdge Firefighter Gateway and a MODBUS metering system. Mypower chose this proven hardware to provide reliable control, emergency isolation, and accurate data logging without additional cost.

Now that the installation is complete, TCL Packaging will return its investment in 3.0 years, safeguard its finances from fluctuating grid prices, and boost its reputation as a packaging sustainability leader.

Key facts and predictions

529.20 kWp (1176 panels) installed.
488,890 kWh of energy produced per annum.
33.1% projected first year return on capital invested, before capital allowance benefits.
4.15p/kWh - the equivalent forward purchase price of 11.3 million units of electricity over 25 years including estimated operating & maintenance costs.
3.0 years - system payback before finance, tax and capital allowance and grant benefit.
94.5 tonnes of CO2 emissions avoided per annum.
26% of the annual electricity demand met by solar.

“We are delighted with the solar installation delivered by Mypower. The project was completed with minimal disruption to our operations and has provided exactly the solution we were looking for. Since commissioning, the system has consistently exceeded our generation expectations, although we recognise that this has been helped by an exceptionally sunny start to the year. Overall, we are extremely pleased with both the installation process and the performance achieved so far.”

John Hallett, Compliance Manager at TCL Packaging Ltd.

"From day one, it was about making sure the system could handle the conditions on site and still perform reliably. With the environment on the roof, the technology in place makes sure the system runs as it should and TCL packaging has a clear view of how everything is working.”

Tom Sivil, Mypower's Project Manager

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