Manufacturing company in Dayton, Ohio

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A manufacturing company in Dayton, Ohio wanted to reduce operating costs and stabilize long-term power pricing. Because manufacturing loads fluctuate throughout the day, the client needed a feasibility study that went deeper than simple “kWh savings” including rate structure impacts and a realistic ROI.

Our feasibility scope included:

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• Detailed energy-use profiling using 12–24 months of utility bills

• Evaluation of solar’s interaction with demand charges

• System design assumptions (roof mount + optional carport evaluation)

• Production forecast + degradation assumptions

• Capex benchmarks and financing scenario model

• A go/no-go recommendation with risk analysis

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Recommendation: Proceed with solar using a design sized to avoid oversizing and maximize financial performance.

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Results (Feasibility Findings)

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• Recommended system size: ~410 kW DC

• Estimated annual production: ~505,000–560,000 kWh/year

• Estimated electricity offset: ~35–45%

• Estimated Year 1 savings: $58,000–$74,000

• Estimated payback range: 5.4–6.9 years

• Estimated IRR range: 14%–19%

• Estimated 25-year net benefit: $1.05M–$1.55M