Multi-national Car Manufacturing Business
Sector: Automotive
Background
Hyperion Zero was appointed to deliver full technical design, DNO grid-connection application, CDM documentation, and the final handover package for a complex 4.6 MW rooftop solar PV installation at the Unipres Manufacturing facility in Sunderland. Hyperion Zero acted as principal technical lead for all engineering, compliance, and DNO-related activities.
The Challenge
The facility includes multiple roof levels, ventilation equipment, cable trays, mansafe systems, and structural limits. Designing a system of this scale required detailed obstruction mapping, multi-roof stringing, and shadow analysis. HV equipment, restricted work areas, and controlled HV isolation added further CDM and safety challenges while the site remained fully operational.
Our Solution
Hyperion Zero delivered detailed PV*SOL modelling, optimised layouts, shading studies, and full string and inverter configuration. Over 18,000 modules and 77 inverters were incorporated across multiple roof zones. A full DNO G99 submission, fault-level work, and export review were completed. CDM documentation covered working at height, HV hazards, and structural risks, concluding with a full O&M and handover package.
Full PV*SOL modelling and optimised multi-roof design
Complete G99 DNO application and fault-level assessment
Comprehensive CDM package for HV, structural, and access risks
Full O&M, schematics, and compliance handover package
Outcomes & Benefits
4.6 MW PV system designed across multiple roof levels
Estimated generation: 4,119,942 kWh per year
CO₂ savings: approx. 2.1 million kg annually
Full CDM, O&M, and handover documentation delivered
Successful DNO application for one of the region’s largest rooftop PV systems
Complex shading, structural, and HV constraints fully resolved
Services Provided
Click on each service to find out more about how we can help with your next project.Bespoke Solar PV System Design & Optimisation
Tailored solar PV designs for maximum performance and return throughout the UK
End-to-End DNO Application Support (G98/G99/G100)
We take the hassle out of DNO applications throughout Scotland and the UK
Solar PV In-Depth Feasibility Studies
Clear, data-driven view of your project's potential.