Toyota Boshoku’s Solar Project Powers Illinois Plant Sustainably
Discover how Toyota Boshoku America’s 5.7-MW solar array transforms its Illinois plant’s energy use, slashing costs and emissions while boosting local jobs and biodiversity with clean, affordable power.
Key Takeaways
- Toyota Boshoku’s 5.7-MW solar array powers 85% of its Illinois plant
- Project avoids upfront costs via a power purchase agreement
- Solar farm generates over 9.5 million kWh annually, cutting 6,800 tons of CO2
- Local jobs and pollinator habitats boost community and environment
- Project aligns with Toyota Boshoku’s net-zero carbon goal by 2050
In a bold stride toward sustainable manufacturing, Toyota Boshoku America (TBA) has unveiled a 5.7-megawatt solar array adjacent to its Lawrenceville, Illinois plant. This ground-mounted solar farm, sprawling across 17 acres, is set to supply approximately 85% of the plant’s electricity needs, marking the largest onsite solar installation in Toyota Boshoku’s global portfolio. The project, a collaboration between TBA, Onyx Renewables, Sol Systems, and Nelnet Renewable Energy, not only stabilizes energy costs amid rising prices but also advances the company’s ambitious carbon neutrality goals. Beyond powering automotive interiors for Toyota vehicles, this initiative breathes new life into the local economy through job creation and enriches the environment with pollinator-friendly habitats. Join us as we explore how this solar project reshapes energy use in manufacturing, challenges myths about clean energy costs, and sets a replicable model for sustainable industry.
Powering Manufacturing Sustainably
Imagine a sprawling 17-acre solar farm humming quietly beside a bustling automotive parts plant. That’s the reality at Toyota Boshoku Illinois (TBIL), where a 5.7-megawatt solar array now generates over 9.5 million kilowatt-hours annually—enough juice to power roughly 880 homes. This clean energy powerhouse supplies about 85% of the plant’s electricity, a remarkable leap toward sustainability in manufacturing. Kenji Sugito, TBIL’s president, puts it plainly: installing this solar system is a clear step toward greener production.
This project isn’t just about slashing emissions; it’s about stabilizing energy costs in a market where prices can spike unpredictably. By locking in affordable, clean power through a power purchase agreement (PPA), Toyota Boshoku sidesteps the hefty upfront costs typically associated with solar installations. The result? Predictable energy expenses that free up capital for innovation and growth. It’s a win-win that challenges the myth that sustainability always comes with a price premium.
Collaborating for Clean Energy Success
Behind every solar panel lies a story of teamwork and shared vision. Toyota Boshoku America partnered with Sol Systems, who originated and developed the project, Onyx Renewables, which acquired and operates the solar farm, and Nelnet Renewable Energy, the engineering and construction expert. This alliance allowed TBA to leapfrog common hurdles like upfront investment and complex project management.
Anna Toenjes from Sol Systems highlights how this collaboration delivers more than just energy savings—it fosters workforce development and environmental stewardship. For example, at least 15% of the project labor came from qualified apprentices earning prevailing wages, injecting skills and income into the local community. This model debunks the myth that clean energy projects are isolated tech ventures; instead, they’re engines of economic and social progress.
Enhancing Community and Environment
Solar farms often get a bad rap for swallowing land, but Toyota Boshoku’s project flips that narrative. Surrounding the solar array is a pollinator-friendly habitat, seeded with native plants chosen in consultation with the Illinois Department of Natural Resources. This buzzing oasis supports bees and butterflies, vital players in local ecosystems, while reducing maintenance like mowing and chemical use.
Moreover, the project’s location in an “energy community” — a designation tied to local unemployment and fossil fuel job numbers — unlocked federal support, underscoring its role in revitalizing Lawrence County’s economy. By employing local labor and suppliers during construction, the project pumped new spending into the area. This holistic approach proves that clean energy can nurture both nature and neighborhoods, challenging the myth that green projects neglect local needs.
Aligning Energy with Corporate Goals
For Toyota Boshoku America, this solar array is more than a power source—it’s a cornerstone of their sustainability journey. The company aims for net-zero Scope 1 and 2 carbon emissions by 2050, and this project slashes approximately 6,800 tons of CO2 annually, equivalent to removing 1,500 cars from the road. Ryan Hunt, TBA’s vice president, calls it a significant step toward reducing the company’s carbon footprint and supporting local communities.
This initiative also reflects a broader Midwest trend where manufacturers adopt behind-the-meter renewable energy to meet corporate mandates and leverage federal incentives. By stabilizing energy costs and reducing emissions simultaneously, Toyota Boshoku challenges the myth that environmental responsibility and financial prudence are mutually exclusive. Instead, they show these goals can power each other forward.
Setting a Replicable Solar Model
The ribbon-cutting ceremony on May 28, 2025, celebrated more than just a solar farm—it marked a replicable blueprint for sustainable manufacturing. Toyota Boshoku plans to expand similar solar projects across its U.S. plants, signaling a commitment to clean energy beyond Lawrenceville.
This model—partnering with developers to avoid upfront costs, prioritizing local workforce development, and integrating environmental stewardship—offers a roadmap for manufacturers hesitant about renewable energy’s complexity or cost. As Patty Rollin from Onyx Renewables notes, such collaborative projects drive real progress and public support. For industries balancing growth with green goals, Toyota Boshoku’s solar success lights the way forward.
Long Story Short
Toyota Boshoku America’s Illinois solar array stands as a beacon of what’s achievable when vision meets collaboration. By harnessing clean energy to power 85% of its plant, the company not only slashes carbon emissions by thousands of tons annually but also secures long-term financial predictability without upfront capital burdens. The project’s thoughtful integration of workforce development and ecological stewardship—like pollinator habitats—demonstrates that sustainability isn’t just a buzzword but a multifaceted commitment benefiting communities and the planet alike. For manufacturers wary of clean energy’s complexity or cost, Toyota Boshoku’s approach offers a clear, actionable blueprint: partner smartly, invest in local talent, and align energy strategy with broader environmental goals. As the company eyes replicating this success across other U.S. facilities, the message is clear—clean, affordable energy is not just the future; it’s a present-day game changer.