Installation Commissioned: 17/07/2025
Our teams have installed a 1.76MWp roof mounted solar PV system for Komatsu UK Ltd based in Birtley, Tyne & Wear.
Project Overview
The system consists of 3,912 panels and is expected to generate 1,641,862 kWh for the machinery manufacturer each and every year, potentially saving them just under £400,000 on their energy bills annually.
Driven by the company’s commitment to sustainability, the system will also enable them to reduce their carbon output by 369,994 kg of CO2e yearly.
Having originally looked at funding their system using a Power Purchase Agreement, AR Power suggested using Asset Finance which made the project cash positive from year one due to the monthly loan repayments being significantly lower than the money they would save on energy costs from the grid.
Introduction
Komatsu UK Ltd are manufacturers of construction and mining equipment with their site situated in the North East of England.
The Komatsu Group takes sustainability very seriously and they have been working on reducing their carbon footprint over a number of years.
Some of the actions Komatsu UK Ltd have taken include utilising daylight harvesting and occupancy sensors, replacing office and factory lighting with LED units, optimizing factory heating, lighting and compressor run times using their building management system, ongoing modernization of production equipment including replacing older welding robots and CNC machines, installing IE3 motors in their paint plant, and replacing an old on-site compressor with a much more efficient variable speed drive unit.
Their site uses a large amount of electricity due to their production machinery. They have four large CNC machines, 15 welding robots, 50 manual welding stations, 4 paint processes. They also use around 100 cranes and manipulators which allow them to move large fabrications into position. In addition they also have office lighting, air conditioning and all of the IT equipment required to run the business.
Stuart Reid, Managing Director of Komatsu UK Ltd said “Given the significant amount of electricity we use and the large amount of space we have on our factory roof, solar was the next logical option for our sustainability journey.”
Komatsu made initial enquiries with a number of providers looking at both direct investment and PPA agreements. They did a lot of modelling using various assumptions for the future cost of energy from the grid, and they were not 100% sure about going down the PPA route. It was at this point that AR Power suggested funding the system using Asset Finance.
Looking at a 10 year agreement with the panels reverting to Komatsu UK at the end of that period, enabled Komatsu to be cash flow positive every year for the solar installation. On this basis, Komatsu made the decision to progress with the leasing option.
Stuart added “Of the initial proposals they looked at AR Power’s was very clear about the equipment that would be installed and it was also very competitive. Their suite of accreditations and certifications gave us confidence in their capabilities and this came across in the meetings we had leading up to appointing them for the project.
“This was supported by visits to some of their previous customers who spoke very highly of them, and our engineering team were impressed with AR Power’s knowledge and expertise and their meticulous attention to detail when it came to system specification, fire safety, and site safety.”
Installation
We were contacted by the team at Komatsu UK Ltd as Paul Blanchard, previous Managing Director at Komatsu UK Ltd had heard about our strong reputation in the area through the North East Automotive Alliance, an association both companies are proud to be part of.
Following on from a discovery call and after receiving their half hourly energy data, our in-house teams were able to start work on creating a bespoke proposal for the machinery manufacturer detailing system size, cost, energy savings, carbon saving and funding options.
Our in-house teams designed a 1.76 MWp SolarEdge Technologies rooftop solar PV system consisting of 3912 panels and 13 SolarEdge inverters, 57km of cabling, and is estimated to generate 1,641,862kWh of energy each year.
If will also dramatically reduce their carbon output by 369,994 kg annually, significantly contributing to their sustainability initiatives and carbon reduction goals.
Fire safety in solar is of strong importance with any installation and we take every consideration into account when designing a system. The SolarEdge system has a lot of built in features such as low voltage when the AC power is disconnected, and ARC detection, however we also included a firefighter gateway and a direct link to Komatsu’s main fire alarm system in the design.
Komatsu UK Ltd are a well-known, multi-national manufacturer of construction equipment, with a very comprehensive selection process when appointing new suppliers. Thankfully, with our suite of accreditations and vast amounts of experience, AR Power were able to meet all required criteria and were appointed as their preferred solar installer.
Our in-house teams and the project team at Komatsu had a number of meetings leading up to the deployment of the system to discuss the project and how we could ensure all CDM requirements were met, maximising health and safety for all, and minimising disruption to the day to day operation of the site.
The installation spans across 2 buildings, their main building and a warehouse.
Due to both buildings being in close proximity of each other, our teams had to opt for a bespoke scaffolding solution which was fixed into the building to ensure there was still access for key deliveries which Komatsu would receive over the 6 month project timeline.
In and around the site were 16 fire exits and pedestrian walkways which we had to work our designs around when considering people working overhead and positioning of our loading bays. Each lift to the roof was meticulously planned in-line with Komatsu’s delivery schedule so there was no disruption and to maximise safety. Netting was installed to scaffolding to protect those below.
Our HSE Manager, Project Manager and operations team have worked closely with Komatsu’s 10-person project team throughout the process to ensure the project runs smoothly. The two teams have met weekly to discuss progress and to ensure everyone is kept up to date with the progress and to discuss what will happen the following week to minimize disruption.
Once all 300m of Scaffolding was in place around the site and a fall arrest system was installed, our teams began installing the system to the warehouse, making the roof lights safe by installing mesh over the top of them. Once this was complete, we were able to fix the rails to the roof and put SolarEdge optimisers in place ready for the panels to be installed. While this was taking place, our in-house electricians were preparing the area where the inverters were being installed and carried out the necessary work to accommodate for the cable runs to the roof.
Once the installation was complete on the warehouse our teams began work on the main building following the same installation process.
For both installations, we were required to make alterations to the building, making 1200mm x 300mm ducts in the walls so cables could enter the building. Lintels were put in place as part of this alteration to maximise building stability. An underground trench also had to be dug to accommodate for cable runs.
Our in-house electricians have built bespoke racking for the inverters to be placed in both plant rooms. Once all panels are installed, the cables were pulled approximately 65m to the inverter room and installed accordingly.
When connecting the system to their main supply, we coordinated a full electrical shut down which took place out of hours on a Saturday to minimise any disruption to Komatsu’s day to day operations.
As with all installations, once the system was commissioned, we provided a full handover with the team at Komatsu.
Both parties are pleased to report that there has been no disruption to their operations while the system has been deployed.
Testimonials
“The installation has gone very well, from start to finish, the service we have received from AR Power has been excellent. From the initial discovery calls about the project, providing guidance, through to weekly meetings, communication, and dedication to site safety, AR Power have demonstrated that they are experts at what they do.
“The quality of installation is impressive, it’s obvious their teams take great pride in their work. Everything is symmetrical, cabling is very tidy, and their teams have been polite and courteous and followed all site guidelines.
“We are very happy with the service we received from AR Power and how the project has been deployed. I fully believe we made the right choice in appointing them and would recommend them to anyone else considering solar.” Stuart Reid, Managing Director, Komatsu UK Ltd.
AR Power’s Comments
Stephen Armstrong, Head of Commercial at AR Power said “This is AR Power’s largest rooftop commercial solar panel installation to date, and we are proud to be working with such a prestigious and globally renowned name. To be trusted by such a large company is a testament to the excellent work we provide and our dedication to site safety.
“We are delighted that everything went smoothly, which is down to a fluid and open chain of communication between the two companies, having regular meetings and being available to answer any questions when needed.”
If you would like to discuss installing solar for your organisation, contact AR Power today for your free consultation.
