Duo Plastics is a leading UK manufacturer specialising in sustainable packaging solutions, catering to major clients such as The Regatta Group, Tesco, QVC, and JD Sports, and other top-tier retailers. With a 44,000-square-foot warehouse and 110 staff members at their Manchester manufacturing site, Duo Plastics has demonstrated a strong commitment to sustainability and reducing their environmental impact, in alignment with growing supply chain expectations.

6
Weeks Installation Time On Site

106,799
kg Of Carbon Saved Annually

504,070
Total annual
energy generation

557
KWp Total Project Size

Project Details
Duo Plastics
Duo Plastics’ Manchester site consumes a significant amount of electricity to power its manufacturing processes. With energy costs rising and growing environmental pressures on businesses, Duo Plastics was seeking an energy solution that could both mitigate rising costs and further its Environmental, Social, and Governance (ESG) targets. Although not currently facing mandatory regulations, Duo Plastics anticipates future legislative pressures regarding sustainability, particularly due to increasing scrutiny from supply chain partners. The key challenge for Duo Plastics was finding an efficient solution that would contribute to carbon reduction without affecting operations or requiring large capital expenditure.

Installation Size: The rooftop solar installation consists of 1,042 solar panels and 12 inverters, covering a significant portion of the available roof space

Capacity and Energy Generation: The system has a capacity of 557.47 kWp and is expected to generate approximately 504,070 kWh annually. This accounts for around 7% of the site’s total energy consumption.

Project Timeline: The installation commenced during September 24 through to November 24 with a total project timeline of six weeks.
The Process
01 Clear Solar Energy Goals
Duo Plastics partnered with Shawton Energy, which specialises in fully funded renewable energy solutions. For this project, Shawton Energy designed and installed a rooftop solar photovoltaic (PV) system under a Power Purchase Agreement (PPA). This allowed Duo Plastics to benefit from renewable energy without the upfront capital investment typically associated with such projects.
02 Bespoke Turnkey Solution
Key aspects of the solution
- Installation Size: The rooftop solar installation consists of 1,042 solar panels and 12 inverters, covering a significant portion of the available roof space.
- Capacity and Energy Generation: The system has a capacity of 557.47 kWp and is expected to generate approximately 504,070 kWh annually. This accounts for around 7% of the site’s total energy consumption.
- Project Timeline: The installation commenced during September 24 through to November 24 with a total project timeline of six weeks.
- Post-installation, Shawton Energy implemented an advanced monitoring system to track the performance of the solar installation in real time. This proactive approach ensures that Shawton Energy can optimise energy savings and quickly address any issues that may arise.
- Shawton Energy offered a fully funded solution through a Power Purchase Agreement (PPA), eliminating the need for Duo’s upfront investment. In return, Duo agreed to buy the generated solar power at a fixed, lower rate than grid prices, providing immediate cost savings and long-term price stability. This PPA model allowed Duo to benefit from solar energy without financial risk, aligning with their sustainability and financial goals.
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The Result
Despite the system covering only a portion of the site’s energy needs, it provides notable financial and environmental
benefits:
- Carbon Emissions Reduction: The solar PV system is expected to save 106,799 kg of CO2 emissions annually, significantly contributing to Duo Plastics’ carbon reduction goals.
- Energy Savings: Although solar energy will account for a relatively modest portion of the site’s electricity consumption, Duo Plastics stands to save approximately £12,000 annually on energy costs. While this figure reflects the current low grid rate, it offers a hedge against future energy price increases.
- ESG and PR Benefits: This project aligns with Duo Plastics’ broader ESG objectives, enhancing their sustainability credentials. As supply chain partners increasingly expect greener operations, the installation boosts Duo Plastics’ profile as an environmentally responsible company.
Shawton Energy’s fully funded rooftop solar installation provides Duo Plastics with a solution that addresses their sustainability goals while ensuring long-term financial savings. The system positions Duo Plastics as a leader in the packaging sector’s move towards greener, more sustainable manufacturing, meeting future supply chain and regulatory demands head-on.

“Sustainability is at the core of everything we do at Duo – in terms of culture, our products, and how we operate. As we strive to innovate in our product development and methods of manufacturing, we also want to ensure that we incorporate more sustainable practices in how we run our business. This project is a significant step forward and we’re delighted to be partnering with Shawton Energy as they help us to deliver on our environmental objectives.”
Dale Brimelow, Operations Director