Delivering the UK’s largest power stack battery installation

A landmark commercial battery storage project for a global aviation business

The background

When global aviation specialist AJW Group approached us, they already had a substantial solar PV system installed at their operational headquarters near Horsham in West Sussex.

As a 24-hour operation serving more than 1,000 airlines across over 100 countries, AJW consumes a huge amount of electricity around the clock. While their existing solar installation generated significant clean energy during the day, much of that electricity was being exported back to the grid.

At the same time, the business still relied heavily on grid electricity outside daylight hours.

The solution was clear: large-scale battery storage.

What followed became an ambitious commercial battery storage project – and the largest power stack battery installation completed in the country to date.

Project goals

AJW wanted to:

Maximise the value of its existing solar PV system
Store excess renewable energy generated onsite
Reduce their long-term electricity costs
Improve their energy resilience and backup capability
Strengthen their sustainability credentials
Future-proof operations against rising energy costs

To achieve this, the solution needed to integrate seamlessly with AJW’s existing infrastructure while minimising disruption to a business operating 24 hours a day.

Challenges

We had three challenges to overcome during the project’s design and installation.

Challenge one: Delivering the right battery capacity

One of our biggest technical challenges was the lack of export data from the existing solar system. Without detailed export figures, accurately sizing the battery installation required careful analysis and modelling.

We gathered half-hourly consumption and solar generation data, as well as tariff information and operational requirements, then worked with trade-only solar wholesaler Alternergy to determine the optimal battery system size for the site. Using Orkestra financial modelling software, a 1.1MW system was deemed to be the right size to balance performance, return on investment and capital expenditure.

Challenge two: Completing the installation in severe weather

The project was installed during February in extremely challenging weather conditions. Despite torrential rain throughout the installation period, our team maintained progress to ensure the project was delivered on schedule.

Commercial projects of this scale require not only technical expertise but also disciplined project management, coordination and attention to detail.

Challenge three: Making the final connections

The most critical phase of the entire project came during the final electrical connection.

Because AJW operates continuously around the clock, shutting down the building’s electrical systems for an extended period simply wasn’t possible. We coordinated with every team onsite to arrange a two-hour window between 6am and 8am to complete the final integration safely and successfully.

The final switch-over was completed on time, safely and with minimal disruption to AJW’s operations.

The solution

We installed five Sungrow Power Stack battery systems, delivering a total capacity of 1.1MW.

The Sungrow Power Stack is an advanced all-in-one commercial battery storage solution featuring:

Integrated battery racks
Intelligent energy management system (EMS)
Built-in liquid cooling
Real-time monitoring and optimisation
Advanced electrical safety protection
Integrated fire detection and suppression systems
Scalable architecture for future expansion

Because AJW already had an operational solar PV system in place, the installation could be connected directly on the AC side, simplifying integration and commissioning.

The five power stacks now operate together as a single intelligent energy storage system, capturing excess renewable energy generated during the day and making it available when the site needs it most.

The results

Immediate impact

The impact of the installation was immediate. AJW can now retain significantly more of the clean electricity generated onsite rather than exporting it back to the grid.

This has resulted in:

Reduced electricity costs
Improved utilisation of renewable energy
Greater energy independence
Increased resilience during grid interruptions
Reduced carbon impact

AJW Group’s Estates & HSE Director Ashley Hedger told us: “We’re retaining far more of the clean energy we generate onsite rather than exporting it. Our electricity costs have come down noticeably, and we’ve significantly improved our energy resilience. And if there are any grid issues, we have backup power available.”

Supporting sustainability goals

Beyond operational savings, the installation also supports AJW’s wider environmental commitments. The project contributes directly to the aviation industry’s broader sustainability ambitions and AJW’s own commitment to supporting net zero targets by 2050.

Ashley added: “Beyond the financial side, this battery installation has reinforced our commitment to sustainability and made our operations more environmentally friendly and efficient. “It’s exactly the kind of investment that positions us as a forward-thinking, responsible business.”

Delivered with precision

Throughout the installation, we worked closely with AJW and technology partner Alternergy to ensure every detail met the highest standards. Sales Manager for Alternergy, Laura Piscitelli, said: “We observed Sopoco’s double checks of all the cable connections, runs and full system tests. We were impressed by the whole team – they were involved in making sure the install was pristine, including areas that would never be seen.”

Return on investment

The system is expected to pay for itself within approximately five years.

With an anticipated battery lifespan of 15-20 years, the project represents a major long-term financial and operational advantage for the business.

“This project demonstrates exactly what modern battery storage can achieve for high-energy commercial operations. “For businesses already generating solar power, battery storage unlocks the full value of that renewable energy while improving resilience and reducing costs. We are immensely proud to have delivered the biggest power stack battery installation in the UK to date.”

Sopoco MD David Tweet