How Bowler Plastics future-proofed three sites with solar

In South Africa's manufacturing sector, keeping the lights on is no longer just a facilities concern - it’s a business-critical strategy. Between rising electricity costs and pressure to meet sustainability targets, manufacturers are having to rethink how they power productivity.

Few understand this better than Bowler Plastics, a recognised leader in South Africa’s rigid plastic packaging industry. With customers across multiple key markets and an unwavering reputation for quality, Bowler knew that energy resilience couldn’t be an afterthought. It had to be designed into their operations - proactively and permanently.

The brief: Powering growth while reducing risk

Like many forward-thinking manufacturers, Bowler Plastics set out to reduce its reliance on the national grid, lower operating costs, and stabilise its energy supply. But their ambition went further: they wanted to build a long-term energy strategy that supported continuous production, reduced their environmental impact, and aligned with their values as a responsible, future-focused business.

In short, Bowler wasn’t just looking for solar - they were looking for a partner to help them future-proof their manufacturing operations.

The solution: Three sites, one vision

RenEnergy worked closely with Bowler’s leadership to design and implement tailored solar PV systems across three key production sites:

• Bowler Clifford - supported by a robust Asset Management plan including four site visits per year, four full cleans, four electrical inspections, continuous monitoring, and monthly performance reporting.

• Bowler Philippi - designed to optimise load offset and maximise available roof space.

• Bowler Harris - integrated with site-specific infrastructure to deliver cost-effective energy performance.

Each system was engineered to meet the site’s technical and operational requirements while aligning with budget, timelines, and production schedules. What made this project stand out was the collaborative mindset from both teams - a shared commitment to getting it right, from design through to commissioning.

“By integrating solar across three of their key sites, we've co-created a solution that not only reduces costs and environmental impact, but also strengthens their operations for the future.”
- Claude Peters, Managing Director, RenEnergy Africa

Installation in progress

The challenges: Customisation, coordination, continuity

Delivering three commercial-scale systems across operational manufacturing environments is no small task. Each site had its own infrastructure constraints, energy load profiles, and safety protocols.

For RenEnergy, the challenge was balancing these complexities with one non-negotiable: no disruption to production.

Close collaboration with Bowler’s internal teams was key. Insights gained from the first installation at Clifford Road informed the roll-out of subsequent sites, ensuring smoother implementation and stronger performance across the board.

“Their openness to collaboration and commitment to the project made it possible to deliver high-performing systems with minimal disruption. I’m proud of what we achieved together.”
- Bertus Geldenhuys, Head of Asset Management, RenEnergy

The impact: From reactive to resilient

Today, Bowler Plastics benefits from:

• Significant reduction in grid dependency

• Lower operational costs across three facilities

• Improved energy stability

• Measurable progress toward sustainability and carbon-reduction goals

More than just a solar rollout, this project is a blueprint for how South African manufacturers can transition from reactive energy management to strategic energy leadership.

“RenEnergy’s quality of work is second to none. I’m looking forward to continuing our partnership as our energy requirements evolve.”
- Arnold Reinecke, Maintenance Manager, Bowler Philippi

What this means for South African manufacturers

This case study is about more than Bowler Plastics. It reflects a wider truth facing the manufacturing sector: energy resilience is now an advantage. The businesses that address it early - with the right partners and strategies - are better positioned to manage risk, control costs, and scale sustainably.

RenEnergy has deep experience in delivering tailored energy solutions for manufacturing clients across South Africa. Whether you're running a high-throughput production facility or planning for growth, we can help you design and deploy energy strategies that protect your performance and your profit margins.

Ready to take control of your energy future?
Get in touch to explore a solar solution tailored to your manufacturing operation.