Supporting One of the UK’s Largest Window and Door Manufacturers on Its Sustainability Journey
Green Revolution successfully delivered a large-scale commercial solar installation for Emplas, one of the UK’s leading manufacturers of windows and doors. The project demonstrates how carefully planned renewable energy solutions can deliver significant financial savings, reduce environmental impact, and future-proof energy-intensive manufacturing operations, all without disrupting day-to-day business.
The Challenge
As one of the largest producers of windows and doors in the UK, Emplas operates a high-output manufacturing facility that consumes approximately 1.3 million kWh of electricity per year, equating to electricity bills of around £25,000 per month. This means they needed to find a long-term solution to help them reduce both carbon emissions and operational costs.
The key challenges included:
- Reducing energy costs without disrupting factory operations
- Lowering carbon emissions in line with sustainability commitments
- Delivering a large-scale solar system safely on an active industrial site
- Addressing the condition of an ageing roof before installing solar panels
The building itself was approximately 30 years old, and the existing roof was no longer in ideal condition for supporting a long-term solar installation. Any solution needed to provide reassurance, longevity and peace of mind before panels could be installed.
Our Solution
Green Revolution provided a fully managed, turnkey solution, covering every stage of the project. Our partnership-led approach and taking the time to understand Emplas’s operational needs, sustainability goals and long-term plans were key to the success of this project.
Roof Replacement and Preparation
Before solar installation began, it was agreed that the roof would be replaced and reclad. This ensured the building was future-proofed and gave Emplas complete peace of mind. The new roof also improved insulation, helping to further reduce energy usage across the site.
Solar Installation
The system includes:
- 1,558 solar panels
- 610 kW inverters
A design optimised for maximum generation without impacting factory operations.
At peak, the project involved over 20 contractors on site, including scaffolders, roofers, electricians, solar installers and media teams. Coordinating multiple trades on a live industrial site required detailed planning, strict health and safety procedures, and constant communication.
Managing a Live Manufacturing Environment
One of the most impressive aspects of the project was how smoothly the installation ran, despite the complexity of the site.
The Emplas factory operates continuously, with hundreds of staff moving in and out across different shifts. Green Revolution worked closely with Emplas’s operational team to ensure:
- Safe working zones were clearly defined
- Staff movements were unaffected
- Installation schedules were carefully planned
- Communication remained constant throughout
The result was a seamless installation with no disruption to manufacturing output, a key reason Emplas chose Green Revolution as its delivery partner.
Going the Extra Mile
As part of the project, Green Revolution proposed a unique addition: spelling “EMPLAS” across the roof using the solar panels themselves.
This was achieved without using any additional panels and without impacting system performance or generation. Located next to Sywell aerodrome, the branding is clearly visible from the air, making a bold statement about Emplas’s commitment to sustainability.
The Results
The Emplas solar system is now fully live and delivering long-term value. For Green Revolution, the project stands as a strong example of how large-scale commercial solar can be delivered safely, efficiently and collaboratively, even in the most demanding operational environments. The impact of the solar installation has been immediate and measurable.
- Electricity bills reduced by approximately 50% per year
- System expected to pay for itself in around four years
- Long-term protection against rising energy costs
- Reliable, clean energy generated on site
- Reduced carbon emissions
- Greater resilience against future energy price increases
From an environmental perspective, the benefits are equally significant:
- 158 tonnes of CO₂ saved per year
Equivalent to:
- 30,400 trees planted
- 3,400 long-haul flights avoided over the system’s lifetime
Even during the shorter days of autumn and winter, the system is already performing exactly as predicted.
Ready to Cut Energy Costs and Future-Proof Your Business?
If you’re running an energy-intensive commercial site, rising electricity costs and sustainability targets can feel like constant pressure. The Emplas project shows what’s possible with the right partner, a carefully planned solar installation that reduces bills, lowers carbon impact and fits around live operations without disruption.
At Green Revolution, we design and deliver commercial solar panels and battery storage solutions tailored to how your business actually works. From roof assessments and upgrades to large-scale installations and long-term performance, we manage everything with clear communication at every stage.
Whether you’re looking to cut operating costs, strengthen your sustainability credentials or protect your business against future energy price rises, we’ll help you make the switch with confidence.
Talk to our team today to see how much you could save and how quickly your investment could pay back. Clean energy isn’t a plan, it’s a smart business decision you can make now.