Bifacial photovoltaic system drastically reduces food industry emissions

Integrating photovoltaic (PV) solar farms into industrial processes can dramatically reduce greenhouse gas emissions, offering a viable route for decarbonizing the food sector, according to a new study published in Energies. The study, titled “The Use of Renewable Energy Sources in the Food Industry and the Reduction of CO₂ Emissions: A Case Study of a Simulated PV Installation”, combines simulation modeling and environmental lifecycle analysis to evaluate how solar energy, particularly from bifacial PV modules, can power mass packaging operations while slashing carbon emissions.

Focusing on a high-energy-demand process, packaging beverages in heat-shrinkable film, the authors modeled two PV farm configurations (monofacial and bifacial) and assessed their performance using the PVSyst simulation tool. They then integrated the electricity outputs from these installations into three different power supply scenarios to measure and compare their carbon footprints using SimaPro LCA software.

How do bifacial PV modules impact energy yields?

The study’s core technical analysis revolved around designing a 1 MW photovoltaic farm at a Polish food industry facility. Two variants were simulated: one using traditional monofacial monocrystalline modules and the other using bifacial monocrystalline modules with identical rated capacities. The farms were arranged under identical environmental conditions and layout configurations to ensure comparability.

Simulation results revealed that the bifacial modules achieved approximately 7.3% higher annual energy yields than monofacial modules. While monofacial systems outperformed bifacial ones slightly in Poland’s winter months, due to limited light reflectivity (albedo), bifacial systems delivered superior performance throughout the rest of the year. Notably, the bifacial system generated 1,162,434 kWh annually, enough to meet the energy needs of the packaging process in ten out of twelve months. Only in January and December did energy production fall short, meeting 82% and 47% of demand, respectively.

This result is particularly significant given the narrowing price gap between the two technologies. In the context of industrial-scale investments, the improved performance of bifacial modules is sufficient to justify their selection under typical Central European climate conditions. The researchers emphasized the importance of module inclination and local radiation data, which heavily influence performance outcomes in such installations.

Can PV power fully sustain industrial packaging processes?

Beyond performance simulations, the study explored the feasibility of replacing traditional power sources in food industry packaging lines with solar energy. Using actual energy consumption data from a Polish packaging facility, the authors calculated the monthly energy demand for producing 10,000 beverage bottle packs in 6 × 1.5 L formats.

Three energy supply variants were examined:

• Variant A: Electricity from Poland’s national energy mix
• Variant B: Electricity from the same mix, with additional natural gas used for the film-shrinking stage
• Variant C: Electricity exclusively from the designed PV installation

The analysis found that the bifacial PV system could meet or exceed energy demands in most months, enabling near-total decarbonization of the mass packaging process. During months of surplus, the additional energy could be redirected to other industrial operations at the same facility.

Simulation data revealed temperature-related energy losses were the most significant factor limiting PV efficiency. For both systems, losses from module heating hovered around 3.6%. The study suggested that implementing cooling technologies or optimizing module placement could further enhance efficiency in real-world applications.

What is the environmental impact of switching to solar power?

The study’s environmental analysis, conducted using the IPCC 2013 GWP 100a method, focused on comparing carbon emissions under the three energy supply variants. The results were stark: Variant C (powered by solar PV) produced a carbon footprint of 504 kg CO₂ eq per functional unit, compared to 1150 kg (Variant A) and 1200 kg (Variant B), amounting to a reduction of nearly 80%.

Detailed emissions data showed that Variant C reduced carbon dioxide, methane, and nitrogen oxide emissions dramatically. CO₂ emissions alone dropped from 16.7 kg/FU to just 1.94 kg/FU. Methane and nitrogen oxide emissions saw similar declines, from 1.55 to 0.487 kg and 2.58 to 1.31 kg per FU, respectively.

Interestingly, supplementing the process with gas (Variant B) had little impact on carbon dioxide but slightly increased methane and nitrogen oxide emissions by 2–5%. The researchers emphasized that PV installations incur most of their emissions during the production of system components, with operational-phase emissions being nearly zero.

These findings align with previous studies cited by the authors, which estimate average emissions of 950 g CO₂/kWh for coal-fired electricity and just 40–50 g CO₂/kWh for solar electricity from monocrystalline modules. The study reinforces the consensus that solar energy can play a critical role in meeting decarbonization goals in energy-intensive sectors.

Implications for industry and energy transition

This integrated analysis bridges the gap between technical performance modeling and environmental impact assessment. By using real process data, the researchers demonstrated that well-designed photovoltaic farms can offer both energy security and sustainability benefits to the food manufacturing industry. The bifacial PV installation not only met most energy needs but also delivered drastic emissions reductions without requiring radical changes in process equipment.

For businesses, especially those in energy-intensive sectors like food packaging, these results signal an actionable pathway to align with increasingly stringent environmental regulations and rising consumer expectations for sustainability. The study recommends the integration of bifacial PV modules where feasible and highlights the need for further analysis on economic returns and operational scalability.

Challenges remain, particularly in sourcing critical PV components and improving module recycling. But with emissions savings as high as 80%, and energy self-sufficiency achievable for most of the year, this research supports broader adoption of solar PV as an industrial power source.