Innovative supply chain for low-carbon commercial solar
From panels to impact:
Annual Energy Production: 1,400 MWh/ yr
Environmental value: 134t carbon offset/ yr cutting Vulcan’s carbon emissions by 35%
Social value: provides a replicable model for NZ’s manufacturers
1.17 MWp commercial solar system
Sunergise delivered a 1.17 MWp commercial solar system at Vulcan’s Hamilton facility. Instead of importing mounting rails from overseas, we worked with Vulcan to use its own extrusion line to manufacture the rails that hold the commercial solar panels in place, using low-carbon aluminium billet sourced from within New Zealand. The result is the aluminium industry’s largest commercial solar installation in NZ, and a solar energy project that sets a new benchmark for what a truly local, low-carbon supply chain can look like. The article looks at Vulcan’s transition to solar PV, highlighting the innovative part of this project.
The Challenge
Aluminium extrusion is one of the more energy-hungry processes in manufacturing, resulting in high energy bills amid rising energy costs. Vulcan needed a way to lower energy costs and reduce the carbon footprint of its operations and its products without the upfront costs that usually comes with a commercial solar investment of this scale.
Sunergise’s Commercial Solar Power Solution
Sunergise proved that out-of-the-box thinking pays off. Rather than importing mounting rails overseas, Vulcan’s own extrusion facility was used to manufacture the rails for its own system — on the very site where the solar panels would go on the roof. Funded through Sunergise’s SunPlus™ Power Purchase Agreement (PPA), Vulcan pays only for the solar electricity generated, with no upfront capital expenditure, while Sunergise manages system performance, operation and maintenance. It’s a model that lowers cost, lowers embodied carbon and lowers future carbon offset, all while reducing dependence on grid electricity and high energy costs.
Low-Carbon Innovation: Project Highlight
This is where the project stands apart. The mounting rails were extruded at Vulcan’s own Hamilton facility, using low-carbon aluminium billet from Tiwai Point — sourced, extruded, and installed all within New Zealand. From raw billet to finished infrastructure, the supply chain never left Vulcan’s own operations, cutting embodied carbon of the solar system and creating a replicable blueprint for other New Zealand manufacturers.
A Word from our Client
“We are proud to have installed the largest rooftop system in NZ’s aluminium industry. While the emissions reductions are significant, the real value lies in building a more resilient and secure energy strategy for the future. This investment reduces our exposure to market volatility and strengthens the long-term sustainability of our operations.”
Zubair Khan, Commercial Leader, Vulcan
