How SDI Services Saved $500k Tracking Solar Panel Damage

When you’re managing large-scale solar installations, damaged panels aren’t just frustrating; they’re expensive.

The team at SDI Services implemented Orca Scan to track solar panel deliveries and document damage the moment materials arrive. This created a simple system that protects both their people, projects and margins.

In fact, in one project alone, they saved over $500,000 by capturing damaged materials at delivery.

Here’s how they did it 👇

A little bit of context

SDI Services delivers end-to-end utility-scale solar projects across more than 35 states.

For Rosario Mendoza, Logistics Superintendent, protecting materials before installation isn’t optional. It’s essential.

Having worked in the solar industry since 2014, he understands the complexities involved in large installation projects. Before implementing Orca Scan, the team relied on pen, paper, photographs, and a constant stream of emails to try to prove where damage had occurred, often slowing work down on site.

While solar panel maintenance systems are available, most focus on tracking panels after installation. Rosario needed something that worked before installation, when materials first arrived on site.

The challenge

Solar panels don’t always arrive on site in perfect condition. Often, the packaging looks fine, but once the pallet is opened, the damage in transit becomes apparent.

Without proof of damage at the point of delivery, SDI Services’ installation teams risked being held responsible.

If they couldn’t prove the panels were damaged before installation, the company had to pay for replacements themselves. This would dramatically increase the cost of a project.

Documenting this damage was also incredibly time-consuming. The team would take photos of the damaged panels, email them to the client, and then stop production until someone from the client side verified the damage.… this could take anywhere from 15 minutes to an hour!

This quickly became a daily problem, and the team needed a way to document damage and prove it was not caused during installation.

That’s when he discovered Orca Scan.

The solution

Rosario and the team use Orca Scan to document materials the moment they arrive on site.

On one Orca sheet, when pallets arrive on site, the team use iPads to capture a photo in Orca Scan and record:

• Barcode
• Wattage
• Supplier
• Multiple images of the delivered product
• Damage Type
• Images of any damages
• Location
• Notes
• Received by

This creates a clear record of the condition of all materials delivered.

On a second Orca sheet, the team logs any damaged or affected panels, including any photos or notes. All of these details are time-stamped, providing a comprehensive audit trail of delivery damage and allowing panels to be returned or exchanged.

Since every scan is automatically time-stamped, data can also be cross-referenced with delivery paperwork, helping the team understand exactly which panels need replacing.

Even when working in areas without internet access, Orca Scan continues to record every scan. Once the device reconnects, the data automatically syncs and updates the sheet.

Once the data is updated, Rosario exports the sheet to Excel, where each entry includes a shareable link to the images stored in Orca Scan.

At the end of each day, he shares this with clients so they can simply click and view the evidence of damage.

Was the solution successful?

The impact of introducing Orca Scan was immediate. In one project alone, the team documented 105 damaged panels worth over $500,000.

Because the damage was recorded and time-stamped in Orca Scan, the team could clearly prove the panels were damaged before installation. Clients were happy to review and approve the reports at the end of the day, preventing SDI Service from absorbing the cost.

The data that Orca Scan provides also allows the team to:

• Know exactly how many panels are available on site
• Record every damaged panel with photo evidence
• Track how many spare panels remain
• Notify clients when additional materials are required

Perhaps most importantly, the team no longer needs to stop production when damage is discovered, as both the installation team and their clients now have full visibility into the condition of the materials arriving on site.

Following its success, Rosario is already rolling Orca Scan out across additional projects and exploring new ways to use it across the business, including tracking tools, equipment, and fleet assets such as buggies, forklifts, and skid steers.

What started as a way to document damaged solar panels has quickly become a system that helps the team protect materials, maintain production, and keep large-scale solar projects running smoothly.

Thank you

A huge thank you to Rosario and the whole team at SDI Service for sharing your story with us 🙏