Performance Analysis of Solar Photovoltaic Integration in Liquid Carton Packaging Manufacturing

Energy-intensive processes such as flexographic printing, extrusion coating, slitting, compressed air generation, and chilled water production make liquid carton packaging manufacturing a major electricity consumer, increasing the need for cost-effective and sustainable energy solutions. This study evaluates the real-world performance of a 679 kWp grid-tied solar photovoltaic (PV) system integrated at the 11 kV level in a liquid carton packaging factory in Nairobi, Kenya, operating under regulatory export control constraints that require full on-site consumption of PV generation. Using measured operational data from energy monitoring platforms, including Sunny Portal, 1.31.8 Schneider EcoStruxure, and Sphera Cloud 8.17.2, system performance was assessed in accordance with IEC 61724-1, focusing on final yield, capacity utilization factor, grid offset contribution, and carbon emissions reduction. The results show that the system generated 617 MWh over the assessment period, corresponding to an average daily final yield of 2.49 kWh/kWp·day and a capacity utilization factor of 10.38%. On-site PV generation supplied approximately 17% of the plant’s annual electricity demand and avoided about 277.7 t CO2 emissions. Performance benchmarking against comparable installations in Kenya, Morocco, Malaysia, Senegal, and Uzbekistan indicates that the lower observed yield is primarily driven by curtailment and industrial load-matching limitations rather than inadequate solar resource or component inefficiency. The findings demonstrate that meaningful electricity cost savings and emissions reductions can be achieved in energy-intensive manufacturing environments despite export restrictions while highlighting the importance of improved load alignment and data-driven operational strategies to enhance PV utilization.