Case Study: Castello Italia – Expansion of the Photovoltaic Plant

In September 2022, Inveco Holding signed a contract with Castello Italia for the construction of a 600 kW rooftop photovoltaic plant.

Thanks to the robust collaboration between the two companies, a significant expansion of the facility was initiated in 2024.

This development not only demonstrates the success of the partnership but also strengthens the commitment of both companies to sustainable growth and technological innovation.

The pre-expansion plant

Technical specifications of the existing system

The pre-existing photovoltaic plant covers an area of 2,880 sq m, featuring 1,116 Jinko Solar Tiger Pro 72HC 540W photovoltaic modules.

The total power output is 602.64 kW, distributed across a roof with an east-west orientation, perfectly adapted to the slope of the structure’s nine spans.

Energy management

Five Sofar 100KTL inverters manage energy transformation, converting the direct current produced by the panels into alternating current, delivering a total power of 500 kW.

The placement of the modules has been strategically designed to avoid shading and to maintain minimum distances from skylights and openings (EFC).

The project was completed on January 24, 2023, with the connection to E-Distribuzione’s MT network.

Energy Production

In 2023, the facility produced a total of 651,240 kWh, of which over 70% was self-consumed by Castello Italia, while the remainder was fed into the grid.

This contributed to significant savings in energy costs and improved the company’s production efficiency.

Why the new facility?

Reasons for Expansion

With the aim of increasing energy autonomy and further reducing emissions, a new phase of expansion of the facility began in 2024.

The project involves both the extension of the rooftop installation and the construction of a ground-mounted system on ballasts.

 

Advantages of the Ground Installation

The decision to use ballasts not anchored to the ground allows Castello Italia to have a flexible and dismantlable solution, perfect for future productive expansions.

It has already been planned for the current ground-based system to be repositioned on a new industrial roof, aligning with the company’s growth projects.

With this expansion, an annual production of approximately 1,000,000 kWh is anticipated, ensuring greater energy independence, up to 35%, and a reduction in pollutant emissions.

The current facility

Technical Details of the Expansion

The expansion of the photovoltaic system includes:

• 44 modules of 570 W on the rooftop
• 378 modules of 570 W ground-mounted

In total, 422 additional 570 W modules have been installed, amounting to a total capacity of 240.54 kW.

The rooftop expansion adhered to the original layout, making optimal use of the space freed up by optimizing the previous system.

The 44 modules placed on the rooftop add a capacity of 25.08 kW, distributed among the less loaded existing inverters.

Ground installation setup

Regarding the ground-mounted system, the maximum installable power capacity is 215.46 kW, with panels arranged in an east-west configuration to maximize productivity while avoiding shading issues.

Corridors have been maintained for emergency exits and to facilitate maintenance of the system.

The 60 kg concrete ballasts ensure stability for the modules, with an optimal tilt of 8 degrees to maximize energy production.

Soluzioni tecniche per l’efficienza

The 125 kW SOFAR inverter has been installed near the room housing the existing inverters to facilitate the management of the energy produced.

The plant design took into account the presence of an electrical substation to the south, with an optimized string layout to prevent productivity losses due to shading.

 

Conclusions

The photovoltaic system at Castello Italia is ready for final connection to the grid.

The collaboration between Inveco and Castello Italia demonstrates how sustainable innovation can support industrial growth while simultaneously improving energy efficiency.

This project serves as a concrete example of how photovoltaic technology can be integrated into industrial environments to achieve sustainability and competitiveness goals.

Analysis by Engineer Matteo Pierotti and Dr. Giuseppe Gallo – Technical Office.