Toyota Boshoku America Powers Manufacturing Facility With 5.7-Megawatt Solar Project

Rhea-AI Summary

Toyota Boshoku America (TBA) has completed a 5.7-megawatt solar project at its Illinois manufacturing facility in partnership with Onyx Renewables, Sol Systems, and Nelnet Renewable Energy. The ground-mount solar array, spanning 17 acres, will meet 85% of Toyota Boshoku Illinois' electricity needs and generate over 9.5 million kilowatt-hours in its first year. The project, TBA's largest onsite solar installation to date, was developed without upfront capital investment through a power purchase agreement (PPA). Notable features include workforce development initiatives with 15% of project labor allocated for qualified apprentices, pollinator-friendly habitat implementation, and federal support as an "energy community." This initiative supports TBA's goal of achieving net-zero carbon emissions by 2050 while providing cost-effective, sustainable energy solutions.

Positive

• Project will meet 85% of the facility's electricity needs with clean energy
• No upfront capital investment required through PPA structure
• Expected to generate over 9.5 million kilowatt-hours in first year
• Helps stabilize energy costs amid rising prices
• Contributes to company's net-zero carbon emissions goal by 2050
• Received federal support as an 'energy community'

Negative

• None.

Insights

Clean Energy Infrastructure Expert

Toyota Boshoku's 5.7MW solar project demonstrates strong corporate sustainability commitment while providing significant cost savings and environmental benefits.

This 5.7-megawatt solar installation represents a substantial commitment to renewable energy for Toyota Boshoku America's manufacturing operations. The system's ability to fulfill 85% of the facility's electricity needs is particularly impressive for industrial manufacturing, which typically has high energy demands.

The project's 9.5 million kilowatt-hours of expected annual generation translates to meaningful economic benefits. With industrial electricity rates in Illinois averaging around $0.08-0.10/kWh, this could represent approximately $760,000-950,000 in annual electricity costs now secured through the PPA structure, providing both cost stability and predictability in an era of volatile energy markets.

The power purchase agreement (PPA) model employed here is noteworthy for requiring zero upfront capital from Toyota Boshoku while still delivering immediate energy savings. This financial structure has become increasingly popular among manufacturers seeking to reduce operational costs without diverting capital from core business investments.

From an implementation perspective, the 17-acre ground-mount array demonstrates efficient land use for the energy output. The inclusion of pollinator-friendly habitats shows attention to ecosystem services beyond just clean energy generation – these plantings improve soil health, support local biodiversity, and can reduce maintenance costs compared to traditional gravel or turfgrass installations.

The project's classification as an "energy community" installation unlocks additional federal incentives under recent legislation, likely improving the economics further. The focus on prevailing wages and 15% apprenticeship labor requirements aligns with emerging best practices in the renewable energy sector that ensure clean energy transitions support quality local employment.

This installation positions Toyota Boshoku America at the forefront of automotive supply chain sustainability, creating both operational resilience through energy independence and progress toward their stated 2050 net-zero carbon emissions goal.

New solar project with partners Onyx Renewables, Sol Systems, and Nelnet Renewable Energy to meet 85% of Toyota Boshoku Illinois' energy needs while supporting local jobs and ecosystems

LAWRENCEVILLE, Ill., May 29, 2025 /PRNewswire/ -- Toyota Boshoku America (TBA), Onyx Renewables, and key project partners gathered today for a ribbon-cutting ceremony to celebrate the completion of a 5.7-megawatt solar project that will fulfill 85% of electricity needs at TBA's Illinois plant with clean, affordable energy. The event featured remarks from the president of TBA, the local chamber of commerce, and representatives from project owner and operator Onyx Renewables as well as project partners Sol Systems and Nelnet Renewable Energy.

As energy prices rise and the urgency to reduce carbon emissions grows, manufacturers across the U.S. are seeking more sustainable, cost-effective energy solutions. TBA recognized the need to both stabilize energy costs and contribute to the company's broader sustainability goals. TBA chose to partner with Sol Systems, which originated and developed the project, to install a solar farm that maximized the energy produced by locating the system on land adjacent to Toyota Boshoku Illinois (TBIL)'s Lawrenceville manufacturing facility. Onyx Renewables then acquired the project, offering immediate energy savings to TBA and TBIL under a power purchase agreement (PPA) without any upfront capital investment.

"This project is a testament to what's possible when manufacturers, clean energy developers, and local communities work together toward shared goals," said Anna Toenjes, Associate Vice President of Impact & Business Development at Sol Systems. "From Day 1, Toyota Boshoku brought vision and dedication to the table, and we're proud to have developed a project that will deliver long-term economic and environmental benefits — from long-term energy savings to workforce development and pollinator-friendly land use."

The newly completed ground-mount solar array, which spans approximately 17 acres adjacent to TBIL's manufacturing facility, is expected to generate more than 9.5 million kilowatt-hours of electricity in its first year. The project marks TBA's largest onsite solar installation to date and is a significant milestone in the company's ongoing efforts toward carbon neutrality.

"We see it as our responsibility to reduce our environmental impact. With the installation of a large-scale solar panel system at our U.S. facility, we're taking a clear step toward more sustainable manufacturing," said Kenji Sugito, TBIL President. "We remain committed to environmentally conscious practices that support a better future."

"This project reflects our commitment to reducing our carbon footprint and our dedication to supporting the communities where we operate. It is also a significant step towards our goal of achieving net-zero carbon emissions by 2050," said Ryan Hunt, Vice President of TBA. "We're proud to partner with companies like Onyx, Sol Systems, and Nelnet to bring clean, reliable energy to Lawrenceville."

Onyx Renewables, a leading developer, owner, and operator of clean energy infrastructure, completed the project's final development and construction. Nelnet Renewable Energy, a full-service firm specializing in commercial and small-scale utility solar, served as the engineering, procurement, and construction (EPC) partner. Onyx Renewables will continue to partner with TBA as the owner and operator of the project, ensuring it continues to deliver high-quality, affordable clean energy to TBIL.

"This is the kind of collaborative clean energy development that drives real progress and public support," said Patty Rollin, Chief Commercial Officer at Onyx Renewables. "Together with our partners, we are thrilled to deliver a project that reduces emissions, lowers energy costs, and sets a high standard for workforce development."

The Onyx Renewables team worked closely with Nelnet to prioritize workforce development and environmental stewardship by allocating at least 15% of project labor for qualified apprentices and paying prevailing wages. In addition, Sol Systems committed to planting a pollinator-friendly habitat around the system. The plants, which Onyx has selected in consultation with the Illinois Department of Natural Resources, will be seeded onsite, enhancing local biodiversity and reflecting TBA's own vision of sustainability. The project also received additional federal support as an "energy community," designated due to the area's unemployment and fossil fuel employment numbers compared to the national average.

"From the beginning, it was clear that Onyx and Toyota Boshoku America wanted to go above and beyond to set a new standard for solar development that included local jobs and job training," said Alyssa Martin, President of Nelnet Renewable Energy. "The project represents a replicable model for how other manufacturers can meet their energy needs while minimizing environmental impact."

About Onyx Renewables

Onyx Renewables is helping companies create the bridge from today's clean energy reality to tomorrow's possibilities. A leading provider of clean energy solutions nationwide, Onyx's approach ensures expert guidance at every step for our commercial, industrial, and institutional customers. From solar energy and storage to EV charging and beyond, Onyx leverages its wide-ranging industry expertise to develop, finance, construct, own and operate projects, transforming energy and regulatory complexities into simple clean energy solutions that reduce emissions and provide economic savings for our customers. Onyx also partners with developers and EPCs to support, fund, and acquire clean energy projects. For more information, visit https://www.onyxrenewables.com.

About Toyota Boshoku

Toyota Boshoku, one of the world's premium interior systems suppliers and filter manufacturers, develops and produces interior, filtration, and powertrain components. With world headquarters in Kariya City, Japan, Toyota Boshoku Corporation owns Toyota Boshoku America, Inc. (TBA) based in Erlanger, Kentucky. TBA and its affiliates employ over 14,000 Team Members in 23 locations throughout the United States, Canada, Mexico, Brazil, and Argentina. TBA Group is a premier manufacturer of automotive interior systems, which include seat, door trim, headliner, substrate, and carpet in addition to air and oil filters for a variety of customers such as Toyota, BMW, and Subaru. For more information, visit https://www.toyota-boshoku.com/us/.

About Nelnet Renewable Energy

Nelnet Renewable Energy, a subsidiary of Nelnet, Inc. (NYSE: NNI), is a full-service engineering, procurement, and construction (EPC) firm specializing in commercial and small utility-scale solar projects. Backed by the financial strength of its publicly traded parent, Nelnet Renewable Energy delivers turnkey solar solutions that include in-house design, construction, and post-installation services, along with expertise in navigating incentives and financial structuring. The company also supports co-investment opportunities through its affiliated tax equity platform, helping partners achieve competitive returns on impact-driven projects. With a focus on quality, transparency, and long-term value, Nelnet Renewable Energy serves businesses, schools, municipalities, and developers across the country. Learn more at nelnetenergy.com.

About Sol Systems

Sol Systems is an impact-driven Independent Power Producer (IPP) committed to building, owning, and managing clean energy infrastructure that benefits local communities. With over 7 GW of projects across 38 states, Sol integrates energy storage and grid resiliency solutions to deliver reliable, sustainable power to Fortune 500 companies, municipalities, utilities, and schools. Through strategic partnerships and community reinvestment, Sol ensures clean energy development drives long-term economic and environmental benefits. Founded in 2008 and led by its founder, Sol Systems is dedicated to shaping an energy future we can all believe in. For more information, visit www.solsystems.com. 

Media Contacts

Toyota Boshoku America: Ryan Hunt, Vice President, ryan.hunt@toyota-boshoku.com or (859) 655-5127
Onyx Renewables: Jenna Leitgeb, media@onyxrenewables.com or (646)-536-3316
Sol Systems: Jacqueline Mayan, pr@solsystems.com
Nelnet Renewable Energy: Brandi Nye, brandi.nye@nelnet.net or (504) 250-1778

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SOURCE Onyx Renewables LLC; Toyota Boshoku America

FAQ

What is the size and capacity of Toyota Boshoku America's new solar project in Illinois?

The solar project has a 5.7-megawatt capacity and spans approximately 17 acres adjacent to Toyota Boshoku Illinois' Lawrenceville manufacturing facility.

How much of Toyota Boshoku Illinois' energy needs will the solar project meet?

The solar project will fulfill 85% of the facility's electricity needs and is expected to generate more than 9.5 million kilowatt-hours of electricity in its first year.

Who are the key partners in Toyota Boshoku America's solar project?

The key partners are Onyx Renewables (project owner and operator), Sol Systems (project originator and developer), and Nelnet Renewable Energy (engineering, procurement, and construction partner).

What environmental and community benefits does the Toyota Boshoku solar project provide?

The project includes pollinator-friendly habitat implementation, allocates 15% of project labor for qualified apprentices, pays prevailing wages, and contributes to the company's goal of achieving net-zero carbon emissions by 2050.

How is Toyota Boshoku America financing the solar project?

The project is financed through a power purchase agreement (PPA) with Onyx Renewables, requiring no upfront capital investment from Toyota Boshoku America.