From metal to plastic: Circular clamps for the Solarguard
Each year, the number of installed solar panels continues to rise. This increase provides more nesting spots for birds, but it also poses risks to the solar panels. Nesting can lead to fire hazards, damage, and reduced efficiency. European Building Supply (EBS) is a supplier of roofing systems and accessories for both professional installers and DIY enthusiasts. Included in their product range is the Solarguard, a bird deterrent designed to prevent birds from nesting beneath solar panels.
The existing Solarguard with stainless steel clips was due for an upgrade. Therefore, we partnered with European Building Supply to optimize the bird deterrent system.
Introducing the Solarguard PRO!
The Challenge
- Plastic mounting clip;
- Resistant to bird activity;
- Provides adequate clamping force;
- More efficient and ergonomic installation;
- Compatible with all types of solar panels;
- Cradle to Cradle (C2C) certified.
The Solution
The installers secure the stainless steel (RVS) clamps from underneath the panel. It’s a tedious task, often repeated over many kilometers. One advantage of the stainless steel clamps was the clamping force, which we needed to match with the plastic clamp. Additionally, the solution had to be more cost-effective, efficient, ergonomic, and, of course, circular!
The Development
We divided the development process into steps: development, testing, and then adjustments. In total, 30 variants were developed and tested on various solar panels. A key test was achieving the optimal wall thickness. The wall thickness had to provide sufficient strength but also needed to be thin enough to avoid high cycle times (and therefore cost). Of course, these were not the only tests. We also explored pull-tabs to speed up installation, make it easier, minimize efficiency loss, and created clamping points to withstand the force exerted by birds.
Sustainable Process Optimization
With a design that met the requirements, we looked further into ways to make the product more sustainable. With the help of various partners, we ultimately succeeded.
The products from the EBS range are delivered to the construction site in a plastic pallet crate. In this crate, customers can collect plastic remnants, such as the pull-tab that installers cut off to prevent efficiency loss. When the crate is full, they swap it with the next delivery to avoid unnecessary transport.
The company Van Werven sorts, separates, cleans, and grinds the post-consumer plastic. By regranulating this plastic, we can then process it back into products like the mounting clamps. We also deliver the products in a plastic pallet crate, which the social workplace then packages in circular packaging.
The Result
The final result consists of two types of fastening clamps:
- A specific clamp for 80% of the market-conforming panels to improve the speed and ergonomics of installation;
- A universal clamp suitable for any panel, using a tie-wrap closure for DIY enthusiasts.
The specific clamp provides installers with a time saving of nearly 45%. This time saving arises from fastening from the side instead of from the bottom of the solar panel. This method of fastening is also much more pleasant.
The universal clamp consists of two parts and fits on any desired panel. Due to the two parts, the time saving is less, but the DIY enthusiast is primarily looking for convenience. There’s no need to consider the technical specifications of the panel, since this clamp fits on any panel.
The various variants have been incorporated into one mold with interchangeable plates. By taking the different variants into account during the mold setup, our customer can bring a new clamp to market within two weeks for new developments. An additional advantage is the savings on the investment for the mold. The plastic clamps are also much cheaper, allowing EBS to quickly recoup the investment.
The most important result is, of course, that we have worked towards the Cradle-to-Cradle (C2C) concept as much as possible. C2C is about ensuring that all materials used after their life in one product are effectively repurposed in another product. We have contributed to this with the following results:
- Processing approximately 7,500 kg of waste in the first year;
- Setting up optimal processes and designs to minimize machine time;
- Reusable packaging from supplier to customer;
- Reducing CO2 emissions by efficiently loading packaging and trucks;
- Climate chamber testing to establish lifespan.
