Fusion deliver large scale solar panel replacement for Aldi regional distribution centre

We successfully delivered a major renewal project to replace solar panels across two extensive roof areas at Aldi’s regional distribution centre in Bathgate, Scotland.

The site required a new solar system to boost sustainability and generate reliable, efficient energy for its chilled and ambient warehousing operations. A critical element of the project involved responsibly disposing the existing solar panels.

Against strong competition from six other installers, Fusion was chosen to remove and recycle the original panels before installing the latest generation of highly efficient solar system.

The new system is estimated to help Aldi save over £430,000 while providing benefits of on-site self-generation and reduced reliance on the national grid.

TCA Building

System size: 1319.025 kW
Estimated annual electricity savings: £250,246
Systems used: 2046x 645w Longi Panels, 9x Solis-100k-5G PRO, Mounted on Van der valk new ValkPRO+ NextGen Ballasted mounted system

RDC Building

System size: 1229.37 kW
Estimated annual electricity savings: £182,563
Systems used: 7x Solis- 100k-5G PRO, 2x S5-GC60k, Mounted on Van der valk new ValkPRO+ NextGen Ballasted mounted system

The Challenge:

Aldi’s distribution centre in Bathgate is situated between Glasgow and Edinburgh and helps supply the supermarket’s locations across Scotland.

Although the site already featured solar panels across its roofs, they needed to be replaced with a modern system capable of delivering the increased output required to power the facilities’ refrigeration units.

The new system needed to generate over 1,200 KW, supporting Aldi’s wider sustainability ambition to achieve net zero for all emissions from sources they own or control by 2035.

As part of their Scope 1 targets, which cover direct emissions from Aldi stores, offices and distribution centres, Aldi is ensuring its facilities receive electricity by sustainable means – making the installation of a modern solar panel system at Bathgate a vital step.

In addition to designing and installing the new system, the project posed the challenge of removing and disposing of over 3,000 existing solar panels. Under the Waste Electrical and Electronic Equipment (WEEE) Regulations 2013, photovoltaic (solar) panels are classified as electrical waste and must be recycled.

All work needed to be completed with minimal disruption to operations and with an uncompromising focus on safety.

How we’ve helped:

Fusion was chosen through a rigorous competitive bidding process to become principal contractor.

Several potential contractors were assessed for their capability, quality standards and experience.

Fusion’s technical expertise, proven track record of successful installations and commitment to excellence and safety set us apart.

As principal contractor, our team carried out the safe removal of the existing panels and installation of the new system – all within just three months.

To ensure the old panels and inverters were responsibly recycled in accordance with regulations, we partnered with waste consultant and materials recycling company, UBH Group.

Following the removal of the old equipment, we conducted a thorough leak detection test across the roof and carried out any remedial work required to ensure the roof structure was weather-tight and ready for the new solar panels.

The installation process took our team just six weeks. This included installing Solis inverters within the building and securing almost 4,000 solar panels across the two stretches of roof.

Finally, the system underwent final commissioning to ensure everything was safe, effective and would provide many decades of reliable energy.

The system is now powering the building’s refrigeration, reducing operational costs and supporting Aldi’s progress toward its net zero targets.

If your company is looking to implement a solar system of this size, you could save up to 462 tonnes of CO₂ per year compared with using non-renewable electricity.

Back