64.96 kW rooftop solar offsetting 99.7% of electricity at an industrial manufacturer in Barrie, Ontario
99.7% annual electricity offset — the highest in the Green Integrations solar portfolio.
A high daytime load against a roof asset approaching the end of its replacement cycle.
Industrial safety equipment manufacturers typically operate with steady annual electricity demand driven by fabrication equipment, assembly operations, lighting, and facility systems. Reliability and predictability are critical, as production supports safety-critical equipment used in demanding industrial environments.
At Belt Conveyor Guarding’s Barrie facility, the objective was to dramatically reduce reliance on grid electricity while maintaining uninterrupted manufacturing operations. The solar system needed to be sized to closely match the facility’s actual annual electricity usage, ensuring very high on-site solar utilisation without oversizing the installation.
Size to the service. Mount without penetrations.
A rooftop solar PV system was engineered with system capacity and layout determined based on roof availability, electrical infrastructure, and operating patterns specific to industrial safety equipment manufacturing.
Rather than maximizing installed capacity, the design focused on precise alignment between annual generation and annual usage, resulting in a solar system capable of offsetting virtually all of the facility’s annual electricity consumption while integrating cleanly into existing operations. The system reached commercial operation on June 5, 2025.
The numbers, then the consequence.
- 0175,152 kWh of solar electricity generated annually.
- 0299.7% of the facility's annual electricity consumption offset — the highest in the Green Integrations portfolio.
- 03Minimal ongoing reliance on grid electricity for day-to-day operations.
- 04System commissioned June 5, 2025, integrated without disruption to manufacturing.
Equivalent to removing 1 passenger vehicle from Ontario roads annually.
For the facilities and engineering audience.
The system consists of 64.96 kW DC (112 Thornova Solar modules) paired with 50 kW AC via an SMA Tripower inverter, selected for stable operation and monitoring in industrial applications.
TerraGen rooftop racking was engineered to integrate with the existing roof structure and site conditions. The system reached commercial operation on June 5, 2025 without disruption to manufacturing operations.
Facility characteristics that shaped the design.
- Industrial safety equipment manufacturing facility producing conveyor guarding systems
- Annual electricity demand driven by fabrication, assembly, and facility operations
- Existing rooftop suitable for compact, high-utilisation solar deployment
- Annual load profile enabling near-complete electricity offset without operational disruption
What was installed.
Evaluating rooftop solar for a commercial or industrial facility? Understanding how solar aligns with your consumption profile and long-term objectives is the first step.
- ·Roof structural and shading review
- ·Annual production model
- ·Net-Metering interconnection check
- ·Incentive & financing stack
- ·Two-scenario capital plan
