966 kW rooftop solar for a confectionery manufacturer in Newmarket, Ontario

A high daytime load against a roof asset approaching the end of its replacement cycle.

Food and beverage manufacturing facilities operate under demanding electrical and operational conditions. Production lines run continuously, climate control systems operate throughout the day, and downtime is not an option. Electricity demand is both high and predictable, driven by processing equipment, refrigeration, ventilation, and packaging systems that must remain stable at all times.

At the Newmarket facility, the client required a long-term electricity strategy that could reduce exposure to grid pricing while maintaining uninterrupted production. Any solution needed to integrate seamlessly into existing processes, preserve roof integrity, and meet structural safety requirements related to wind and snow loading. Food safety, operational continuity, and electrical reliability were non-negotiable.

Solar was evaluated not as a marketing initiative, but as infrastructure tied directly to how the facility consumes electricity every day.

Size to the service. Mount without penetrations.

A custom-engineered rooftop solar system was designed around the facility’s manufacturing load profile and operational constraints. System capacity, layout, and electrical integration were planned to prioritise on-site consumption rather than exporting electricity to the grid.

A south-facing array orientation was selected to support consistent output, while system sizing was calibrated to match the facility’s annual electricity consumption profile. The result is a rooftop solar system that functions as a core electricity asset rather than a supplemental add-on.

The numbers, then the consequence.

• 011,142,549 kWh of solar electricity generated annually — offsetting 99.6% of the facility's electricity consumption.
• 02965 kW DC system commissioned August 15, 2025 as the most recent and largest phase of an 11-project programme.
• 03$7.2M in verified lifetime savings across all programme phases.
• 04Solar now functions as a core electricity asset, substantially reducing long-term exposure to grid pricing.

For the facilities and engineering audience.

The rooftop solar system consists of a 966 kW DC array paired with 740 kW AC of inverter capacity. A ballasted mounting system was used to protect the roof membrane and avoid penetrations, preserving roof integrity while meeting structural safety requirements.

Structural assessments confirmed the building could safely support the combined load of the solar system, including equipment weight, ballast, and regional wind and snow conditions. The system interconnects under Ontario’s Net Metering program at 600 volts, allowing on-site generation to directly offset grid-supplied electricity.

Commissioning was coordinated with the local utility and the Electrical Safety Authority and completed without disrupting production.

Facility characteristics that shaped the design.

• Continuous production manufacturing facility with high daytime electricity demand
• Significant refrigeration, ventilation, and climate control loads
• Large, uniform rooftop area suitable for ballasted solar deployment
• Predictable annual load profile enabling accurate system sizing and long-term planning

What was installed.