From Production Lines to Profit Lines: How Solar Powers Smarter Manufacturing

In this blog, we explore how rising energy costs are reshaping UK manufacturing, why energy has become a strategic issue for productivity and competitiveness - and how solar is helping UK manufacturers turn one of their biggest overheads into a long-term advantage.

In manufacturing, every penny counts. Margins are tight, competition is fierce and the cost of doing business keeps rising. Amongst all the overheads that manufacturers face, one stands out as both a challenge and an opportunity: energy.

In this blog, we explore how rising energy costs are reshaping UK manufacturing, why energy has become a strategic issue for productivity and competitiveness - and how solar is helping UK manufacturers turn one of their biggest overheads into a long-term advantage.

The cost that never stops ticking
Manufacturing overheads include everything from rent and equipment maintenance to property tax and salaries - the unavoidable costs that keep the wheels turning. But while fixed expenses stay relatively steady, energy costs fluctuate wildly. And when you’re running power-hungry equipment around the clock, even small changes in electricity rates can hit your bottom line hard.

Between 2021 and 2023, UK manufacturers saw average electricity prices rise by nearly 50% (ONS/BEIS). Prices have stabilised since their 2022 peak, but they remain above pre-crisis levels, and volatility is now part of the landscape.¹

Energy is no longer just another utility bill. It’s a strategic business issue that affects productivity, compliance and competitiveness.

Why energy costs matter more than ever
High and unpredictable energy prices put intense pressure on manufacturing margins. For many, that can mean:

•    Squeezed profits – harder to pass on higher costs to customers.
•    Delayed investment – R&D, training and upgrades put on hold.
•    Operational disruption – shifting production to avoid peak tariffs.
•    Reduced global competitiveness – UK firms paying more than overseas rivals.
•    Workforce impact – reduced hours or downtime as costs bite.

The result? Manufacturers are forced into short-term survival mode, sacrificing innovation for immediate savings. But there’s a smarter, more sustainable way to regain control.

Turning a liability into an asset
On-site solar power is transforming how manufacturers manage their energy. By generating clean electricity directly from their own rooftops, businesses can take control of one of their biggest variable costs and turn it into a predictable, long-term saving.

Installing solar isn’t just about cutting carbon. It’s about stabilising costs, boosting resilience and unlocking profit potential. With the right system design, most Plug me in customers achieve payback in just 3–5 years - and then enjoy decades of low-cost energy.

Proven results in manufacturing
Sonifex Ltd – powering innovation with solar
When audio technology manufacturer Sonifex faced rising electricity demands that risked costly infrastructure upgrades, we delivered a 70 kWp solar PV system that now generates 74,000 kWh a year and saves 14.3 tonnes of CO₂ annually. With a three-year ROI and projected lifetime savings of £386,000, the system allows Sonifex to meet its growing production needs without expanding its grid connection. Read more. 

HB Humphries – laser-focused on savings
At Kettering-based HB Humphries, our 145 kWp solar installation is expected to generate £773,000 in profit over 20 years, cutting 378 tonnes of CO₂ in the process. The system achieved a three-year ROI and began saving the company nearly £29,000 in year one - reducing operating costs while improving price competitiveness. Read more. 

These are just two of our 1000+ commercial solar installs – and the benefits are clear:

•    Lower energy bills – self-generation reduces dependence on the grid.
•    Protection from price spikes – predictable, stable running costs.
•    Improved ESG performance – measurable, auditable carbon reductions.
•    Energy security – less exposure to market volatility and supply risks.

Add battery storage, and you can capture excess solar energy to use during high-demand or high-tariff periods, increasing independence and maximising savings.

Why manufacturers are choosing Plug me in
Across the UK, forward-thinking manufacturers are cutting costs and carbon with Plug me in’s solar expertise. Having installed more than 1,000 commercial systems since 2011, we’ve seen first-hand how solar is reshaping energy strategy across the sector - from precision engineering firms to global logistics operators.

Our in-house design and engineering teams ensure every installation is built for performance and longevity. Using advanced technologies like SolarEdge optimisation and monitoring, we maximise generation at module level and keep systems operating efficiently year after year.

With a typical three-year ROI and more than 17,000 tonnes of CO₂ saved to date, Plug me in systems don’t just pay back, they keep performing. And with flexible funding options such as Power Purchase Agreements (PPAs), you can lock in predictable, low-cost energy without upfront capital outlay.

Energy volatility isn’t going away. But with Plug me in, you can take control of it - turning your production lines into profit lines and making energy a driver of performance rather than a cost of doing business.

Talk to us today and let’s get you started on a smart solar journey.

Source ref
¹ Quarterly Energy Prices June 2023