Nelipak
Strategic Solar Planning for Healthcare Manufacturing
Nelipak Healthcare Packaging operates within a highly energy-dependent manufacturing environment where operational continuity, cost control, and sustainability performance all play a critical role in long-term business planning. As energy costs continued to rise and pressure increased around carbon reduction and ESG reporting, Nelipak wanted to assess the viability of large-scale on-site solar generation across its Clara facility. Rather than jumping directly into procurement or installation, the business needed a clear, commercially grounded understanding of what was technically feasible, financially viable, and operationally practical. Shannon Energy was engaged to deliver a detailed Solar PV Feasibility Study designed to provide Nelipak with a structured roadmap for potential solar deployment across both rooftop and adjacent land assets.
The Challenge
Like many advanced manufacturing facilities, Nelipak’s site combines significant daytime electricity demand with operational requirements that leave little room for disruption.
The challenge was not simply identifying where solar panels could be installed. The project required a much deeper assessment of how much electricity could realistically be offset through solar generation, the balance between self-consumption and grid export, and the long-term commercial viability of different installation approaches. Planning considerations, grid connection requirements, operational impact, and long-term return on investment also needed to be carefully evaluated.
Nelipak also needed confidence that any future project would integrate smoothly into existing operations while supporting broader sustainability and energy resilience objectives.
Our Approach
Shannon Energy carried out a detailed feasibility assessment across the Clara facility and surrounding site lands, combining technical analysis, energy modelling, planning review, and commercial evaluation.
Following a full site review and energy analysis, Shannon Energy developed two potential deployment pathways: a 525kWp rooftop solar installation across the Nelipak facility roof structure, and an 818.4kWp ground-mounted solar array located on adjacent lands south of the facility. The study was designed not only to assess generation potential, but to determine how each option would perform within the realities of Nelipak’s operational profile and the Irish energy market.
Particular focus was placed on maximising self-consumption, ensuring the majority of generated electricity could be used directly on-site rather than exported to the grid. Shannon Energy also assessed energy generation potential, export levels, carbon reduction impact, capital investment requirements, long-term electricity savings, payback period, planning considerations, grid connection pathways, and operational integration requirements.
The feasibility study included detailed consideration of rooftop structural suitability, access and maintenance requirements, health and safety procedures, construction methodology, and integration into existing site infrastructure.
Delivery
Technical Feasibility
Shannon Energy carried out a detailed technical assessment of the Clara facility, evaluating rooftop suitability, adjacent land opportunities, projected energy generation, and long-term system performance across both deployment pathways.
Commercial Modelling
Detailed financial modelling was completed for each option, including projected savings, payback period, self-consumption ratios, export levels, and long-term return on investment within the context of Nelipak’s operational profile.
Planning & Integration
The study assessed planning considerations, grid connection pathways, construction methodology, and operational impact to ensure any future deployment could integrate smoothly into the live manufacturing environment.
Outcome
The feasibility study provided Nelipak with a clear and commercially grounded understanding of how solar could support its operational, financial, and sustainability objectives. By combining technical engineering analysis with strategic commercial insight, Shannon Energy delivered a practical roadmap for informed energy decision-making.
1.34MWp
Combined assessed solar generation capacity across rooftop and ground-mounted deployment options.
€6M+
Projected long-term electricity savings identified across both deployment pathways over 25 years.
7,400+ tCO₂e
Estimated carbon reduction potential across the projected system lifetime.
Clarity
A structured roadmap covering feasibility, planning, operational impact, and delivery considerations before procurement or installation.
Start with the Energy Strategy & Solar Readiness Study
A structured assessment that clarifies feasibility, project risks, and the most practical pathway to on-site solar.
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