DHL Coventry
Case Study
Project Size:
900kWp
Energy Produced:
814,000kWh
per annum
Payback Period:
2.6 years
Project Size:
900kWp
Energy Produced:
814,000kWh
per annum
Payback Period:
2.6 years
Igen partnered with Glencar and DHL to design and install a 900 kWp solar PV system at their new carbon‑neutral logistics hub in Coventry. The facility represents DHL’s first operationally carbon‑neutral new-build site in the UK and demonstrates a major step forward in sustainable logistics infrastructure.
The Challenge
DHL’s brief was clear: create a logistics hub that is entirely powered by renewable electricity and maximises energy self-sufficiency while supporting the company’s ambitious carbon‑neutral goals. The project required integrating a large-scale solar PV system with battery storage, electric vehicle charging, and all-electric material handling equipment. Achieving these objectives while ensuring the building met stringent BREEAM standards (ultimately certified as BREEAM Outstanding) and maintaining operational efficiency presented a complex technical challenge.
The Solution
Igen delivered a comprehensive solar solution, specifying over 2,000 high-performance solar panels to achieve a total capacity of 900 kWp. The system was carefully designed to:
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Optimise energy generation based on roof layout and orientation
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Integrate with on-site battery storage to shift peak demand to off-peak periods
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Provide real-time monitoring via the Building Management System for ongoing performance visibility
In addition, the building was designed with 30 electric vehicle charging spaces, fully electric material handling equipment, and a new all-electric tug, enabling the site to operate with minimal reliance on grid electricity and a reduced carbon footprint.
The Results
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Total system capacity: 900 kWp
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Energy generation: sufficient to power the site entirely from renewable electricity
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Carbon impact: first operationally carbon-neutral DHL new-build site in the UK
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Building certification: BREEAM Outstanding
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Operational efficiency: peak demand management via battery storage and real-time energy monitoring
The system significantly increases energy self-sufficiency and reduces reliance on external power sources, while supporting DHL’s broader sustainability and operational targets.
The Impact
This project positions DHL Coventry as a benchmark for sustainable logistics facilities. It demonstrates the feasibility of integrating renewable energy, battery storage, and fully electric operations into high-performing, carbon-neutral logistics hubs. For Igen, the project highlights our expertise in delivering large-scale renewable systems that are fully integrated into modern, sustainable building designs.
Natalie Frow, Managing Director Ecommerce & Retail, DHL Supply Chain UK & Ireland
“As a warehouse that is fully powered by renewable electricity, our new Coventry operation sets the standard for the industry. The highly considered design and fit-out is centred on our three priorities, our people, our customers, and our environment. We’ve created an operation that is not only highly efficient at meeting the demands of omni-channel brands, but it’s a positive space to be in. Since opening applications for vacancies, we’ve had more candidates than any other site which really shows that we’re meeting the needs of the modern workforce and I’m delighted to be welcoming so many new people into the DHL family.”