Commercial Solar and Battery Storage Case Study | Stockport
See how Bee Solar reduced energy costs by £102k for a Stockport manufacturer using a 500 kWp solar and 200 kWh battery storage system.
Client
Peak Manufacturing Co
Location
Stockport, Greater Manchester
System Size
500 kWp / 200 kWh BESS
Completed
2024
The Challenge: Afternoon Demand Charges and CNC Risk at a Stockport Plant
Peak Manufacturing Co in Stockport, Greater Manchester, faced energy-intensive afternoon production spikes, and demand charges comprised 40% of the electricity bill. Standard solar alone could not address those peak demand charges, because the generation peak occurs around midday while highest demand arrived later in the afternoon shift.
The buying decision at this site was driven by two distinct anxieties. For Financial Controllers, the problem was the tariff structure: sharp afternoon spikes in half-hourly demand windows triggered punitive capacity charges. For Operations Directors, the problem was production risk: sensitive CNC machinery required protection from grid faults and outages, effectively demanding UPS-style backup. A solar-only array could generate daytime energy, but it could neither shift that energy into the afternoon peak window nor protect CNC loads during a grid event. For manufacturers facing these specific conditions, exploring dedicated solar for manufacturing sites can provide a deeper understanding of tailored solutions.
Solar-only
- Reduces daytime unit consumption.
- Does not cut demand charges if afternoon spikes exceed generation.
- Provides no backup during grid outages.
- Leaves 40% of the bill (demand charges) unresolved.
Solar + battery storage
- Shifts morning generation into afternoon peak windows.
- Cuts demand charges at the meter.
- Provides UPS-style backup for critical CNC loads.
- Addresses both bill structure and operational risk.
Storage is justified when afternoon peaks do not coincide with generation. At this Stockport plant, the afternoon production spike was the dominant cost driver, and the operational risk was genuine CNC downtime.
The Solution: Peak Shaving with 500 kWp PV and 200 kWh LFP Storage
Bee Solar designed a 500 kWp array paired with a 200 kWh lithium iron phosphate (LFP) battery for Peak Manufacturing Co, Stockport, Greater Manchester, completed 2024. The system's core function is peak shaving: the battery stores surplus morning generation and the EMS automatically discharges during afternoon peak tariff hours. This project is a prime example of how commercial battery storage systems can be configured for dual financial and operational benefits.
System snapshot: 500 kWp solar PV array, 200 kWh LFP battery, EMS-controlled discharge into afternoon peaks, 45 minutes critical load backup for CNC machinery, completed 2024 at Stockport, Greater Manchester.
500 kWp PV array
Generates surplus morning energy for storage and daytime self-consumption across production shifts.
200 kWh LFP battery
Dual duty: peak shaving daily and 45 minutes UPS-style backup for CNC machinery.
EMS dispatch
Automatically discharges stored solar into afternoon peak tariff windows to cut demand charges.
Local delivery
Designed and installed for Stockport industrial stock. See also solar carport installations.
The single 200 kWh LFP battery means the same asset that cuts the bill also protects production uptime, which is why LFP chemistry was selected for this installation.
Outcomes: £102k Saving, 38% Bill Cut, and 5.2-Year Payback
This 2024 Stockport project delivered a £102,000 annual reduction in energy costs, a 38% cut in the total electricity bill, and a 55% reduction in peak demand charges. Payback including battery cost was 5.2 years, with 156 tonnes CO2e saved annually.
Annual energy cost reduction: £102,000 (38% bill reduction)
Peak demand charge reduction: 55% through battery discharge
Payback period: 5.2 years including battery cost
Carbon footprint reduction: 156 tonnes CO2e annually
Production uptime protection: critical load backup for CNC machinery
| Metric | Result |
|---|---|
| Annual energy cost reduction | £102,000 (38% bill reduction) |
| Peak demand charge reduction | 55% through battery discharge |
| Payback period | 5.2 years including battery cost |
| Carbon footprint reduction | 156 tonnes CO2e annually |
| Production uptime protection | Critical load backup for CNC machinery |
The 5.2-year payback includes the cost of the battery, not just the PV array. However, this payback is specific to this Stockport manufacturing site in 2024. Other sites, such as cold storage facilities, data centres, or hospitals with 24/7 demand, have different load profiles so their paybacks will differ.
Related Bee Solar projects demonstrate range, but metrics are not transferable. See also: commercial battery storage, peak shaving, and Stockport commercial solar. For a comparative example, review a parallel solar-plus-storage project.
Next Step: Free Site Survey for Greater Manchester Manufacturers
Every project starts with a free site survey; Bee Solar shows what hybrid solar and battery storage can do for your building. To start your project, call 0161 570 0596.
Free site survey
Models your tariff structure, load profile, and solar generation potential. Understanding how the Smart Export Guarantee works is key to viability.
Design
Engineers PV, battery and EMS around afternoon peaks and export mismatch. Explore solar financing options early.
Install
Local provider for Stockport and Greater Manchester industrial sites with minimal disruption to production.
EMS aftercare
Ongoing monitoring and support. Related service: Solar Batteries.
The hybrid system is worth it when afternoon peaks and export mismatch exist, as they did on this site's 40% demand-charge bill. If peaks align with generation, solar-only may be sufficient.
Frequently Asked Questions
Is battery storage worth it with commercial solar in the UK?
Battery storage is worth it when demand charges dominate your electricity bill, as they did at this Stockport site where demand charges comprised 40% of costs. The 500 kWp / 200 kWh hybrid system delivered a £102,000 annual saving and a 38% bill reduction by shifting morning generation into afternoon peaks.
What is peak shaving on a commercial solar and battery storage system?
Peak shaving is storing solar energy during low-demand periods and discharging it during high-demand tariff windows. On this Stockport system, the 200 kWh LFP battery stores surplus morning generation, and the EMS automatically discharges it during afternoon peak tariff hours.
Why didn’t solar-only fix afternoon demand charges at this Stockport site?
Solar-only could not fix the afternoon demand charges because the plant's peak demand occurred in the afternoon, after the PV array's generation peak had passed. Battery storage was required to time-shift the solar energy into the site's peak demand period.
What is the best solar system for commercial manufacturing use?
The best system is one sized to the site's load profile and tariff structure. At this Stockport precision manufacturer, the optimal configuration was a 500 kWp PV array paired with a 200 kWh LFP battery and an EMS that dispatches stored energy into afternoon peaks, plus 45 minutes backup for CNC machinery.
How much does commercial solar and battery storage cost?
Costs vary by system size, site access, and existing electrical infrastructure, so a precise figure requires a site survey. This 500 kWp / 200 kWh Stockport project achieved a 5.2-year payback including the battery. Contact Bee Solar for a free site survey.
What payback did this 500 kWp / 200 kWh Stockport project achieve including the battery?
This project achieved a 5.2-year payback including the battery cost, driven by a £102,000 annual saving (38% bill reduction) and a 55% cut in peak demand charges. This figure is specific to the 2024 Stockport site.
Why Lithium Iron Phosphate (LFP) for this commercial battery?
LFP was selected because it is appropriate for this site's dual duty of peak shaving and critical load backup. The 200 kWh LFP battery provides 45 minutes of backup for CNC machinery and performs daily discharge cycles for peak shaving.
How long can the battery back up critical CNC loads during a grid outage?
The 200 kWh battery provides 45 minutes of critical load backup for CNC machinery. This allows production lines to complete active cycles and shut down safely.
Does Bee Solar survey commercial sites in Stockport and Greater Manchester?
Yes, Bee Solar surveys commercial sites in Stockport and Greater Manchester. The company designed and installed this 500 kWp / 200 kWh system at Peak Manufacturing Co in Stockport, completed 2024.
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