360 kW Factory Roof Array in Bulgaria

Client Background

A working manufacturing plant with long, low-pitch metal roof runs and an industrial site around it. The roof offered an almost uninterrupted run in one direction, which is unusual and worth exploiting.

Project Challenge

The plant could not stop production for the install, so roof time had to be short and predictable. The roof also had a stated load allowance, which capped how much dead weight the array and racking could add.

Our Solution

TTM monocrystalline modules laid out in continuous rows along the roof runs, on aluminium alloy racking rather than steel so the dead load stayed inside the roof's allowance. The half-cell layout with bypass diodes limits the effect of the roof plant and vents that break up the northern end of the array.

Manufacturing Process

Modules were produced on the automated line, flash-tested and binned, then packed 31 pieces per carton. Racking was pre-assembled as far as shipping allowed so the roof crew had less to build.

Supply Chain Coordination

Racking bundles were grouped by array section and shipped with the modules, so the crew unpacked in build order rather than sorting parts on a live factory roof.

Quality Control

Flash test and power binning before packing, plus visual inspection of glass, frame and junction box seal. Crates sealed and marked before container loading.

Final Result

A 360 kW array running the full length of the factory roof, installed without stopping production in the building underneath.

Customer Benefit

Aluminium racking kept the array inside the roof's load budget, and pre-assembly cut the number of days the install crew had to be on a roof above an operating plant.