Off-Grid Solar & Battery Installation in Devon

From Dudley to Devon: Helping a manufacturer go fully off-grid

An award-nominated project delivered by Starkey Electrical Ltd has helped a Devon-based manufacturer achieve one of the UK’s first large-scale off-grid battery-powered manufacturing systems.

Working with West Country Concrete Products (WCCP), the goal was simple: cut energy costs, reduce carbon emissions, and eliminate reliance on fossil-fuel generators, without disrupting production.

The Challenge

WCCP’s manufacturing site was operating on an outdated generator-based system with no grid connection. This created:

  • High running costs
  • Heavy carbon emissions
  • Unstable long-term energy security
  • Dependence on fossil fuels for continuous production

The brief was to design a fully resilient renewable energy solution capable of supporting heavy industrial demand, while keeping production running.

The Solution

Starkey Electrical Ltd designed and delivered a fully integrated off-grid energy system combining:

  • A 875kWh containerised battery energy storage system
  • A 178kW solar PV array
  • Bespoke installation and lifting solutions for large-scale roof-mounted PV

Before full deployment, a proof-of-concept battery system was tested, and structural assessments were carried out to ensure the roof could safely support the installation.

Once validated, the system was scaled into a full industrial-grade energy solution designed for continuous, high-load operation.

Following successful validation of the initial system, the installation was further expanded with an additional 187.7 kWp solar PV array installed on a second roof, increasing overall generation capacity and further strengthening site resilience and energy independence.

The Results

Since completion, the site has:

  • Operated fully off-grid for over twelve months
  • Required no backup generator usage
  • Achieved a stable, self-sufficient energy supply
  • Significantly reduced environmental impact

The system now provides WCCP with long-term energy resilience and protection against rising electricity costs.

Key Project Stats

  • ⚡ 875kW battery energy storage system
  • ☀️ 178kW and 187kW solar PV arrays
  • 🏭 Fully off-grid industrial operation
  • 🔩 585 solar panels installed (32.5kg each)
  • 📅 12+ months continuous off-grid performance

Project Delivery

This project required more than standard installation work. It involved:

  • Engineering design for a grid-independent system
  • Structural validation of industrial roofing
  • Bespoke lifting methods for safe PV installation
  • Integration of solar + storage into a single operational system
  • Commissioning of a fully autonomous power solution

In Summary

This project demonstrates how large-scale manufacturing sites can transition away from fossil-fuel dependency and move towards reliable, renewable, off-grid power systems.

For WCCP, it’s meant lower emissions, greater energy security, and long-term operational savings. For us? A seriously proud moment, and a real showcase of what’s possible when engineering meets ambition.