Solar for distribution centres
Distribution centres combine the very large roof areas that make warehouses ideal for solar with the substantial and growing electrical demands of logistics fleet operations. Together, these characteristics make distribution centres some of the highest-value commercial solar opportunities in the Welsh market today.
We work with regional distribution centres, last-mile logistics facilities, parcel sortation hubs, retail distribution operations, and third-party logistics providers across Wales.
Roof area and structural opportunity
Modern distribution centres frequently have roof areas measured in hundreds of thousands of square feet, capable of hosting solar installations from one megawatt upwards. The structures are typically designed to modern loading standards with substantial spare capacity, simplifying solar installation and minimising the need for reinforcement.
Roof orientation matters less at this scale because the simple size of the array overwhelms small inefficiencies due to non-optimal angle. East-west split arrays often outperform pure south-facing designs on very large flat roofs because they distribute generation more evenly through the day and better match logistics load profiles.
Fleet electrification and depot charging
The most important emerging trend in logistics is fleet electrification. As electric vans replace diesel models and electric HGVs come into commercial service, depot electrical demand grows enormously, with some operators projecting demand increases of five to ten times within a decade.
Installing solar today and planning electrical infrastructure for future fleet charging gives logistics operators a substantial head start on this transition. The marginal cost of larger DNO applications, larger main switchgear, and ducting for future charger installations is small when included in a current solar project, but very substantial as a retrofit.
- Roof areas typically suitable for megawatt-scale solar
- Strong daytime conveyor and pick equipment loads
- Growing demand from fleet electrification
- Future-proofing for HGV charging infrastructure
- Strong customer demand for low-carbon logistics
Customer requirements and ESG reporting
Major retailers and manufacturers are increasingly placing carbon requirements on their logistics suppliers, including specific commitments to renewable electricity for warehousing operations. On-site solar provides verifiable evidence of compliance that increasingly forms part of contract negotiations and tender responses.
Combining solar with refrigeration and freezer loads
Distribution centres serving food retail and pharmaceutical logistics typically include substantial refrigerated and frozen storage. These loads are continuous and high, providing excellent solar self-consumption alongside the more episodic demand from pick equipment and HGV charging.
Frequently asked questions
What size of system is typical for a distribution centre?
We design distribution centre systems from around 500kW up to several megawatts. The largest constraint is usually grid capacity rather than roof area or budget.
How does this fit with retailer sustainability requirements?
Solar provides verifiable on-site renewable generation that satisfies most retailer ESG reporting requirements. Many of our DC customers cite this as a primary driver.
What about future HGV charging?
Future-proof electrical infrastructure can be included in current projects. We frequently install spare capacity on switchgear, ducting and DNO applications for future deployment.
Can we phase the solar deployment?
Yes. Particularly for very large DCs, phased deployment can manage capital flow while still benefiting from integrated design across phases.
Sequencing solar with fleet electrification
The most successful distribution centre projects we have completed have treated solar, battery storage and fleet charging as a single integrated programme rather than three separate procurements. This approach delivers substantial savings on electrical infrastructure (shared switchgear, shared DNO applications, shared monitoring) and produces a coherent operational system that delivers the lowest possible cost per kilowatt-hour to the fleet.
For operators in the early stages of fleet electrification, even a modest current solar installation establishes the foundation for much larger future deployments. We frequently install initial systems with explicit future expansion plans, including reserved switchgear positions, spare DNO connection capacity, and structural surveys covering planned future array areas. This ensures that subsequent phases can be added without revisiting first-principle decisions.
Health and safety in active distribution operations
Distribution centres are some of the busiest industrial environments in the country, with constant HGV movements, internal vehicle traffic and conveyor operations. Our installation methods are specifically designed for these environments, with strict segregation between our work areas and operational traffic, controlled access for materials lifts, and clear communication with site security and transport teams. We have completed installations at multiple high-throughput DCs without operational impact.
Project sequencing across multiple buildings
Many distribution centre sites comprise multiple buildings, each potentially supporting its own array. Phased deployment across a multi-building site allows capital to be spread, lessons from early installations to inform later ones, and grid connection arrangements to be optimised across the whole site. We routinely produce master plans for multi-building sites that show how a sequence of installations builds towards a target site-wide generating capacity over several years.
Smart Export Guarantee and surplus generation
Even very well-matched distribution centre installations occasionally produce surplus generation, particularly during summer weekends and holiday periods when warehouse activity drops but solar output remains high. Smart Export Guarantee registration captures revenue from this surplus, and we routinely include SEG registration as a standard part of project handover. For larger installations, commercial Power Purchase Agreements with corporate offtakers can deliver materially better economics on the export portion than retail SEG tariffs.