Cobham Service Station – 368.55 kWp (Sept ’25)

As part of its nationwide sustainability strategy, Extra MSA Group has invested in large-scale solar PV at Cobham Service Station, one of the UK’s busiest motorway service areas. Designed and installed by Spirit Energy, the 368.55 kWp system delivers substantial carbon and cost savings while helping Extra move closer to its long-term net-zero objectives.

Why Cobham Chose Solar
Cobham operates 24 hours a day, with continuous demand from retail outlets, restaurants, refrigeration, EV charging points and essential building services. Energy consumption is consistently high, and like many modern service stations, electricity represents a significant operating cost.

Extra recognised that solar PV offered an opportunity to take control of its energy use while strengthening its environmental credentials. By generating clean, renewable electricity on-site, the business can reduce reliance on the grid, protect itself from volatile energy markets, and demonstrate tangible progress toward decarbonising its estate.

The Solar System Design
Spirit Energy’s design team proposed a 368.55 kWp solar PV system optimised for Cobham’s large, flat roof structure. The system comprises:

- 810 × Trina TSM-455NEG9R.28 solar panels (455 W each)
- Arcbox DC side arc fault protection
- 3 × Solis-110K-5G inverters
- Projoy rapid firefighter shutdown system
- Solis solar, export and consumption monitoring system
- SolarFox enhanced monitoring display screen

The array faces 12° from south with no shading, ensuring optimal generation throughout the year. The system is expected to produce approximately 305,159 kWh of electricity annually, offsetting around 68.7 tonnes of CO₂ per year.

With 96% of generated energy consumed on-site, the array is perfectly matched to Cobham’s load profile, maximising self-consumption and overall return on investment.


Installation Highlights
The project was delivered as a turnkey package, including surveys, design, installation and commissioning.

Key aspects included:

- Feasibility and surveys: A comprehensive technical survey and planning submission were completed.

- Electrical configuration: DC cabling was efficiently routed to the inverters, each rated at 110 kW, ensuring balanced load distribution and ease of maintenance.

- Safety and compliance: Installed in accordance with MCS standards and current IET wiring regulations, with all rooftop isolators, labelling and containment designed for long-term serviceability.

- Roof access and safety: A man-safe safety line system was also designed, supplied and installed to enable routine maintenance and cleaning to be carried out safely. Careful consideration was given to the solar array layout to ensure both systems worked in harmony without compromising performance or accessibility.

Installation was carefully planned around the operational requirements of the service station, ensuring uninterrupted site access and business continuity throughout the works.

Financial and Environmental Benefits
At 2025 electricity rates, the system is forecast to deliver annual savings of around £77,000. The investment is expected to achieve a payback period of approximately 4–5 years.

Environmentally, the system will prevent 68.7 tonnes of CO₂ emissions every year -equivalent to planting more than 3,000 trees annually. Over its 25-year lifetime, the installation will contribute more than £1.9 million in cumulative energy savings, supporting Extra’s long-term sustainability and cost-reduction goals.

Conclusion
The Cobham Services solar installation marks a major step in Extra MSA Group’s commitment to operating more sustainably. With a 368.55 kWp array designed for high on-site consumption and robust long-term returns, this project showcases how large commercial operators can achieve meaningful environmental impact while improving operational efficiency.

Spirit Energy is proud to have partnered with Extra MSA on this installation, helping to drive cleaner, lower-cost energy across the UK’s motorway service network. 

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