In today’s dynamic manufacturing world, energy is more than just a utility; it’s the spark that keeps production running. Industrial facilities, powered by massive engines and heavy machinery, often operate 24/7, driving output but also consuming enormous amounts of electricity.
The issues? Soaring energy costs and a growing environmental footprint.
Sometimes it’s like a cycle that often feels impossible to break, but what if your facility could draw energy from a cleaner, more reliable, and cost-effective energy source?
Yes, you heard it right, and that’s where solar power comes in!
As electricity prices continue to rise and corporate sustainability goals become more pressing, manufacturers are rethinking how they power their commercial operations.
Therefore, solar energy is emerging as a game-changing solution, offering reliability, long-term savings, and a sustainable path forward for the Australian manufacturing industry.
In this blog, we’ll explore how manufacturers are successfully implementing solar power, featuring real-world case studies from Cyanergy that highlight both the business advantages and environmental impact.
So, let’s explore how solar energy can help your manufacturing facility reduce costs and enhance efficiency, achieving long-term sustainability.
In this blog post:
- Why Solar Energy Is Essential for Modern Manufacturing Facilities?
- Case Studies from Cyanergy: Real-World Manufacturing Success in Australia!
- Is Now the Right Time for Manufacturers to Transition to Solar Energy?
- Best Practices for Manufacturing Facilities Considering Solar
- Final Notes: Ready To Take The Next Step?
Why Solar Energy Is Essential for Modern Manufacturing Facilities?
In Australia, manufacturing facilities typically have large roof or yard footprints, significant and relatively stable electrical loads, including lighting, motors, HVAC, and other machinery. So, the energy used every day is enormous.
By harnessing the sun’s energy, factories can significantly cut operating costs, reduce carbon emissions, and gain greater control over long-term energy stability.
Beyond the environmental benefits, solar power also strengthens a company’s competitive edge and brand reputation in an increasingly eco-conscious market.
Here we’ve penned down the importance of solar power in the manufacturing industry:
- Energy cost mitigation
- Ensure Operational Continuity & Resilience
- Promote Sustainability and Brand Value
- Increase Asset value & ROI
So, how solar energy reduces manufacturing costs in Australia?
With electricity prices rising and energy market volatility increasing, incorporating solar energy offers a way to reduce grid dependency and lower utility costs in the long term.
Solar panel systems, when paired with battery storage, can help smooth peak energy demand, reduce grid dependence, and improve functioning time.
In larger industries, many manufacturers are under pressure from customers, regulators, investors, and internal stakeholders to reduce their carbon footprint.
Solar helps them to achieve energy freedom, powering businesses with a sustainable energy source.
Solar systems, when sized appropriately and properly optimised, can deliver payback in a few years and continue to provide savings thereafter.
According to Cyanergy’s capability statement, we delivered a 490 kW system that generated 752 MWh for a manufacturing client, with a 37-month payback period.
This shows that industrial-scale solar can deliver real, practical results for manufacturers.
Now, let’s examine solar power solutions for manufacturing facilities, case studies, and best practices to ensure a clear understanding.
Case Studies from Cyanergy: Real-World Manufacturing Success in Australia!
In this part of the blog, we have selected three examples from Cyanergy to illustrate how manufacturing facilities are utilising solar energy.
These are not generic installations; these are production-oriented businesses taking real steps across different states of Australia.
1. Uniplas Mouldings International – Wetherill Park, NSW
Project Overview
- System size: 490 kW solar system installed in staged phases
- Investment: AUD $591,823.71.
- Annual generation: 752 MWh
- Yearly energy costs before solar: approximately $647,000.
- After solar: $456K, which is approximately 55% of the previous
- Payback period: 37 months
Why it matters
For Uniplas, a large industrial manufacturer, the solar system not only significantly reduces their operating energy costs, but the payback of just over 3 years means that the return on investment is also attractive for the business.
The staged approach also allowed them to access multiple subsidies and implement the project rapidly; for example, the first stage of 200 kW was completed in four weeks.
This clearly shows how manufacturing operations can incorporate solar without any significant disruption.
2. AC Laser – Thomastown, VIC
Project Overview
- System size: 99.45 kW
- Annual generation: 141.75 MWh
- Annual electricity cost before solar: $79,000.
- After solar: $38,160, a reduction of more than 50%
- Payback period: 26 months
Why it matters
This is a smaller-scale manufacturing facility compared to Uniplas, yet the results are impressive: a more than 50% cost reduction and a shorter payback period.
This shows that not only large-scale commercial properties but also mid-sized manufacturing operations can benefit from solar, not just large ones.
Insights Gained from the Case
- Don’t wait until your business is huge, as size is scalable.
- The solar system’s size aligned well with the manufacturing load, saving thousands of dollars.
- Rapid ROI shows manufacturing facilities can justify solar as a capital investment for their business.
3. Specialised (Cycling-Industry manufacturer) – Port Melbourne, VIC
Project Overview
- System size: 39.6 kW
- Annual generation: 47.32 MWh
- Electricity cost before solar: $26,720; after solar: $17,770
- Payback period: 45 months
Why it matters
Although smaller, this project depicts that solar energy is a viable option for manufacturing across various sizes and sectors, even in facilities with a relatively small carbon footprint.
The case emphasises sustainability as a business value and how solar can support brand positioning as well as cost savings.
Major Takeaways
- Solar supports both cost and branding sustainability goals.
- Even medium-sized systems can provide meaningful savings.
- The ROI generated must be viewed in terms of both financial and reputational benefits for any business, whether it’s large or small.
Is Now the Right Time for Manufacturers to Transition to Solar Energy?
After knowing the numerous benefits of solar solutions, you may be tempted to go solar. However, transitioning from traditional energy sources to solar energy comes with a cost.
From government incentives to long-term cost savings, the financial case for solar energy is compelling.
Still wondering, is it time for businesses to go solar? Here’s why you should act now:
- Electricity prices continue to rise in many markets, strengthening the return on investment for solar energy.
- Many governments and utilities offer incentives, favourable tariffs, or rebates for industrial solar projects.
- Day by day, the pressure for sustainability reporting and corporate social responsibility (CSR) is intensifying. Manufacturing facilities with high energy loads are often subject to inspection.
- Technology costs have fallen recently, making solar panels and inverters more affordable than ever and reducing payback time.
- With the right sizing and execution, the solar system becomes a long-term asset that pays for itself, releasing capital for other manufacturing investments.
Best Practices for Manufacturing Facilities Considering Solar
Solar can be a powerful game-changer for manufacturing companies and large commercial buildings when implemented correctly.
But that doesn’t mean it’s as easy as flipping the switch.
Therefore, before investing in Solar power, ensure you understand every step that leads to real savings and sustainable success for your business.
1. Conduct a detailed energy assessment & align solar to load
Before installation, it is essential to understand your manufacturing facility’s energy usage patterns, including the peak usage limit, daily load curves, and seasonal variations.
The better the match between system size, orientation, and actual usage, the higher the yield and the quicker the payback.
At Cyanergy, we provide a customised design based on site analysis.
2. Use staging or modular deployment
If you have a large manufacturing site, you may benefit from staging the solar solution in phases.
For example, in Uniplas’s case, the installation was divided into three stages. This enables access to multiple subsidies, enhances cash flow, and mitigates the risk of disruption.
3. Optimise your system size & measure consumption rate
Over-sizing or under-sizing can both cause significant loss in a business. Therefore, the design should minimise waste and maximise the use of solar energy on-site.
As in AC Laser’s mid-sized facility, a 99 kW system fits their load and delivers huge savings.
4. Check your rooftop or plant infrastructure
Is your rooftop compatible with solar panel installation?
For manufacturing facilities, factors such as roof strength, shading, orientation, structural constraints, and maintenance access are crucial.
Ensure the facility can support panels, inverters, wiring, and monitoring systems without compromising building aesthetics.
5. Perform regular monitoring & performance tracking
Everything requires a certain amount of care and maintenance to function properly over time. The story is the same for a solar panel system.
Real-time monitoring allows you to spot performance issues, shading effects, degradation, and inverter downtime.
Cyanergy emphasises continuous monitoring post-installation.
6. Research on financial modelling & payback analysis
When going for solar, always calculate realistic payback periods, ensure system cost fits within capital budgets,
You should also check the available incentives, tax benefits, payback time, and how to stack several rebates for maximum savings.
For example, many Cyanergy projects offer a 2–4 year payback, with several solar rebates that can be combined with the VEU Rebate.
7. Align with sustainability and your brand strategy
In manufacturing factories, incorporating solar energy can be a substantial component of a broader sustainability strategy. Why?
Solar reduces your dependency on harmful fossil fuels, cutting greenhouse gas emissions.
It positions your brand and promotes your business, demonstrating corporate responsibility and improving stakeholder perception.
8. Maintenance & lifecycle planning
Solar systems require periodic maintenance, inverter replacements, cleaning, and monitoring.
So, manufacturing facilities should incorporate service arrangements into their design. Plan for system longevity, degradation, and eventual replacement or upgrade to ensure optimal performance.
9. Consider adding Battery storage
Even though optional, integrating battery storage or demand management can enhance value by enabling peak shaving, reducing demand charges, and storing excess energy for nighttime use or during grid outages.
10. Engage stakeholders and minimise disruption
In manufacturing, you can’t easily stop production. Plan your solar installation during low-production periods, coordinate with your team, and prioritise safety to minimise downtime.
Final Notes: Ready To Take The Next Step?
For manufacturing facilities, solar power isn’t just about being eco-friendly; it’s a smart business move for Australians. Cyanergy’s case studies showed that even large manufacturers can achieve paybacks of 2–4 years, reduce costs, lower emissions, and enhance brand value.
With proper planning, energy assessment, correct system sizing, phased installation, and active monitoring, solar can deliver lasting benefits.
So, if rising energy bills or sustainability goals are on your radar, it’s time to view solar energy as an innovative manufacturing solution, apart from just a renewable energy source.
Reach out to Cyanergy, conduct an energy audit, and engage a solar specialist with manufacturing experience today. Cyanergy is here to help!
