Thwaites
Case Study
Project Size:
645kWp
Energy Produced:
540,000kWh
per annum
Payback Period:
2.8 Years
Project Size:
645kWp
Energy Produced:
540,000kWh
per annum
Payback Period:
2.8 Years
Igen partnered with Interclass and Thwaites Dumpers to design and install a 641kWp solar PV system across two newly constructed buildings at Thwaites’ Warwickshire site. As a manufacturer renowned for producing the highest-quality site dumper trucks on the market, Thwaites continues to lead by example in both product innovation and environmental responsibility. Their recent site expansion provided the perfect opportunity to embed sustainability at the core of their operations.
The Challenge
With energy costs continuing to rise and the manufacturing sector facing increasing pressure to reduce emissions, Thwaites recognised the importance of investing in renewable energy as part of its long-term growth strategy. The brief was clear: design a high-performing, low-maintenance solar system capable of offsetting a significant portion of the site’s electricity demand, while integrating seamlessly with the new building design and construction timeline. Igen worked closely with Interclass, the main contractor, to coordinate installation alongside other construction activities, ensuring minimal disruption and a smooth handover process.
The Solution
To meet the client’s performance and reliability goals, Igen specified a combination of 1,411 Longi Hi-Mo 6 solar panels and five Solis G5 inverters, delivering industry-leading efficiency and long-term durability. The system was strategically designed to maximise solar generation throughout the year, taking into account roof orientation, shading, and energy demand patterns across both buildings.
Key elements of the installation included:
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Total capacity: 641kWp
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Annual generation: Over 500,000 kWh of renewable electricity
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Technology used: Longi Hi-Mo 6 panels, Solis G5 inverters
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Installation sites: Two newly constructed manufacturing and office buildings
Igen’s in-house engineering team managed every stage — from system design and DNO applications through to installation, testing, and commissioning — ensuring compliance with all relevant standards and safety requirements.
The Results
The completed system now generates over half a million kilowatt-hours of clean energy every year, significantly reducing Thwaites’ reliance on grid electricity. This equates to a substantial reduction in both operational costs and carbon emissions. In addition to the financial savings, the system provides real-time performance monitoring, allowing Thwaites to track energy production and environmental benefits via an online dashboard.
The Impact
This installation supports Thwaites’ wider sustainability goals and demonstrates the company’s proactive approach to decarbonising its operations. By choosing solar, Thwaites has taken a major step toward achieving energy independence and contributing to the UK’s transition to net zero. For Igen, the project showcases our ability to deliver complex, large-scale renewable systems in partnership with leading contractors and manufacturers — helping clients unlock the long-term benefits of clean, efficient power.
Mark Chandler, Site Manager, Interclass
“Working with Igen on the Thwaites Warwickshire project was an excellent experience from start to finish. Their team demonstrated outstanding technical knowledge and a proactive approach throughout the design and installation of the 641kWp solar PV system. Despite the challenges of coordinating with multiple trades on a live construction programme, Igen delivered the project safely, on schedule, and to a very high standard. The end result is a first-class renewable energy system that not only meets the client’s performance goals but also sets a benchmark for sustainability across the site.”