Power Your Production Line – Industrial Solar Solutions

Reliable, scalable solar systems designed for manufacturing and industrial operations. Reduce energy costs, ensure production continuity, and improve bottom line profitability.

Why Solar for Manufacturing?

Manufacturing and industrial facilities are among the largest electricity consumers. Electricity typically accounts for 20-35% of operating costs. Industrial solar systems provide stable, predictable energy at fraction of grid rates, directly improving profitability and competitive advantage.

Massive Cost Savings

Reduce production costs by 40-50%. Significant competitive advantage in pricing power.

Production Continuity

Hybrid systems ensure zero production downtime during grid failures. Critical for time-sensitive orders.

Improved Margins

Lock in energy costs for 25 years. Protected against inflation and tariff hikes.

Sustainability Compliance

Meet ESG requirements, ISO 50001 energy management standards.

Scalability

Systems from 50 kW to 10+ MW. Grow capacity as production expands.

Better Unit Economics

Lower per-unit production cost improves competitiveness in global markets.

Industrial Solar System Requirements

Specialized Systems for Demanding Industrial Loads

Industrial Load Analysis:

Industrial facilities have unique requirements:

High consumption: 500-5,000+ units daily
Duty cycles: 16-24 hour operations, 6-7 days/week
Peak loads: Heavy machinery operation during specific hours
Reliability: Production cannot tolerate power disruptions
Power quality: Sensitive equipment requires stable voltage/frequency

System Configurations for Industry:

Configuration 1: Peak Shaving System

Solar covers peak demand hours (9 AM – 5 PM)
Reduces peak demand charges (typically 30-40% of bill)
Grid supplies base load
Ideal for: Demand-charge heavy industries (textiles, food processing)
System Size: 50-200 kW
Benefit: 25-35% electricity bill reduction
Cost: ₹4-5 per watt

Configuration 2: Full Load-Covering Hybrid System

Solar + battery covers most daytime load
Reduces grid dependence by 70-80%
Grid backup for peak spikes
Ideal for: Time-sensitive manufacturing, critical equipment
System Size: 100-500 kW solar + 50-200 kWh battery
Benefit: 50-60% electricity bill reduction + zero downtime
Cost: ₹7-8 per watt

Configuration 3: 24×7 Off-Grid System

Massive solar arrays + substantial battery storage
Complete grid independence
Ideal for: Remote facilities, unreliable grid areas
System Size: 200-1000 kW solar + 200-500 kWh battery
Benefit: Complete energy independence
Cost: ₹8-10 per watt

Configuration 4: Distributed Rooftop + Ground Mount

Rooftop panels on all available surfaces
Ground-mounted arrays in facility areas
Maximizes generation capacity
Ideal for: Large industrial campuses with expansive facilities
System Size: 500 kW – 5 MW+
Benefit: Optimal energy generation
Cost: ₹4-6 per watt (economies of scale)

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Load Analysis for Manufacturing

Understanding Your Industrial Power Consumption

Load Profiling Process:
Step 1: Historical Data Compilation

Collect 12 months of:
– Monthly electricity bills
– Maximum demand (kW) each month
– Peak load hours (if available)
– Seasonal variations
– Growth trajectory

Step 2: Detailed Load Study

Identify:
– Baseline load (essential processes)
– Variable load (production-dependent)
– Peak demand periods
– Low-load periods
– Power factor (efficiency)

Step 3: Sample Load Profile
TEXTILE MANUFACTURING UNIT – LOAD PROFILE

Daily Consumption: 800 units
Operating Hours: 6 AM – 10 PM (16 hours)

Hour | Load (kW) | Notes

——-|——-|————————-

6-8 AM | 200 kW | Start-up, preparatory work
8-12 PM | 350 kW | Full production
12-1 PM | 250 kW | Lunch break, reduced ops
1-5 PM | 350 kW | Peak production (2nd shift)
5-7 PM | 300 kW | Evening shift start
7-10 PM | 150 kW | Limited operations
10 PM+ | 50 kW | Security, minimal systems

Peak Demand: 350 kW (1-5 PM window)
Average Load: 200 kW
Demand Charges: ₹8 per kW (major cost component)

Step 4: Solar System Sizing Based on Load

If peak load = 350 kW

And peak sun hours = 5 hours

Required solar capacity = 350 ÷ 5 = 70 kW (minimum)

Recommendation: 75-80 kW system to account for:
– Inverter losses (3-5%)
– Panel degradation (0.5% annually)
– Weather variations
– Future expansion buffer

Industrial Solar Components

Heavy-Duty Equipment for Continuous Operations

Component	Specification	Function	Industrial Advantage
High-Wattage Panels	400-450W	Generate maximum power per unit area	Requires less roof/ground space
Industrial Inverters	30-500 kW, 3-phase	Convert DC to AC for heavy loads	Built for 24/7 operations, redundancy options
Transformer	Step-up transformer	Integrate with industrial 11kV/33kV system	Enables large-scale integration
SCADA System	Cloud-based monitoring	Real-time plant integration	Optimizes production schedule with generation
Energy Storage (Battery)	50-500 kWh industrial batteries	Backup and load leveling	24/7 operation support
Power Quality Equipment	Harmonic filters, stabilizers	Ensures stable voltage/frequency	Protects sensitive machinery
Firefighting & Safety	DC/AC disconnects, surge protection	Emergency shutdown capability	Meets industrial safety standards
Structural Systems	Heavy-duty racks, concrete foundations	Support massive panel arrays	Withstands high wind, seismic loads

Installation in Industrial Facilities

Minimal Production Disruption – Phased Installation

Phase 1: Planning & Design (2-3 weeks)

Detailed load study and energy audit
Site assessment (roof, ground space, structural capacity)
System design and financial projections
Government approvals and environmental clearances
Procurement of equipment

Phase 2: Infrastructure Preparation (1-2 weeks)

Structural reinforcement if needed
Electrical infrastructure upgrade
Safety systems installation
Staging area setup

Phase 3: Installation (3-6 weeks depending on size)

Ground preparation (if ground-mounted)
Mounting structure installation
Panel installation (phased to avoid disruption)
Inverter and balance system setup
Electrical connections and switchgear

Phase 4: Testing & Commissioning (1-2 weeks)

Performance testing
Load testing with production equipment
Safety compliance verification
Integration with facility management systems
Staff training

Key Feature: Phased Approach

Installation during non-peak production hours (nights/weekends)
No shutdown of critical operations required
Parallel operation testing (old system + solar running together)
Seamless switchover to solar power

Financial Benefits for Industrial

Exceptional ROI for Manufacturing Units

Financial Scenario: 150 kW System for Textile Mill

Investment & Subsidy:
System Cost (150 kW @ ₹5/watt): ₹75,00,000
MNRE Subsidy (30%, ₹15L cap): -₹15,00,000
Additional state incentive: -₹5,00,000
———–
NET INVESTMENT: ₹55,00,000
Annual Operational Savings:
Annual Generation (150 kW, 5.5 hrs/day): 3,00,000 units
Electricity rate: ₹8/unit

Direct Savings: 3,00,000 × ₹8 = ₹24,00,000

Additional Benefits:
– Demand charge reduction (peak shaving): ₹12,00,000
– Accelerated depreciation (40% tax benefit): ₹3,00,000
– SCCL/REC credits (if applicable): ₹2,00,000
———–
TOTAL ANNUAL BENEFIT: ₹41,00,000

25-Year Projection:
Year 1-5: ₹41,00,000 × 5 × 0.95 = ₹1,94,75,000
Year 6-10: ₹41,00,000 × 5 × 0.90 = ₹1,84,50,000
Year 11-15: ₹41,00,000 × 5 × 0.85 = ₹1,74,25,000
Year 16-20: ₹41,00,000 × 5 × 0.80 = ₹1,64,00,000
Year 21-25: ₹41,00,000 × 5 × 0.75 = ₹1,53,75,000
———–
TOTAL BENEFIT (25 YEARS): ₹9,71,25,000

Less: Maintenance & repairs: -₹50,00,000
———–
NET 25-YEAR PROFIT: ₹9,21,25,000

Payback Period: 1.6 years
ROI: 1,676%
IRR: 68%

Key Metrics:

Levelized Cost: ₹2-3 per unit (vs ₹8 grid rate)
NPV (25 years): ₹4-5 crores
Production Cost Reduction: 8-12% (major competitive advantage)

Operational Efficiency & Demand Management

Optimize Production Schedule for Maximum Solar Benefit

Industrial facilities can further optimize savings through strategic scheduling:

Strategy 1: Shift Heavy Loads to Peak Sun Hours
If heavy machinery typically runs 2-4 PM
AND peak solar generation is 11 AM – 3 PM
THEN: Schedule heavy processes during 11 AM – 3 PM
BENEFIT: Direct solar power usage, reduced grid purchase
SAVINGS: Additional ₹2-5 lakhs/yearStrategy

2: Peak Demand Management
If peak demand charges account for 40% of bill
THEN: Reduce peak demand by shifting non-critical loads
BENEFIT: Avoid exceeding demand threshold
SAVINGS: ₹5-10 lakhs/year depending on facility

Strategy 3: Battery Load Leveling
With battery storage:
– Store excess solar during low-production hours
– Deploy during peak grid tariff hours
– Flatten demand curve
BENEFIT: Double savings (reduced peak demand + cheaper night rates)
SAVINGS: Additional ₹5-8 lakhs/year

Smart Control System Implementation:

Our advanced SCADA system enables:

Automated load shifting based on solar forecast
Peak demand prediction and mitigation
Real-time production vs. solar generation coordination
AI-based optimization for cost minimization
Alert system for maintenance needs

Industrial Solar Case Studies

Success Stories from Indian Manufacturing

Case Study 1: Spinning Mill – Karnataka
Profile: 300 looms, 24/7 operations, 4,000 units/day consumption
Challenge: Rising electricity costs reducing profit margins
Solution: 200 kW solar + 100 kWh battery + smart demand management

Results:
– Electricity bill reduction: 48% (₹1.92 crores/year → ₹1 crore/year)
– Production uptime: Improved to 99.8% (from 96%)
– Cost per unit produced: Reduced by ₹8-10 per yard
– Payback period: 1.4 years
– CO2 offset: 500 tons/year (CSR benefit)

Impact: Mill regained market competitiveness, won new contracts

Case Study 2: Food Processing Unit – Maharashtra
Profile: 300+ employees, refrigeration-intensive, peak load 450 kW
Challenge: Demand charges very high due to AC loads
Solution: 180 kW peak-shaving solar system + strategic scheduling

Results:
– Peak demand reduced by 35%
– Electricity bill: Reduced by ₹45 lakhs/year
– Demand charges avoided: ₹20+ lakhs/year
– Production increased 15% (better equipment uptime)
– Payback: 1.8 years

Client Testimonial: “Best capital investment in 5 years. Improved profitability and helped us compete with global operators.”

Case Study 3: Pharmaceutical Manufacturing – Pune
Profile: Strict environmental controls, 24×7 operations, 500 kW peak load
Challenge: Energy costs rising, need for zero downtime
Solution: 250 kW solar + 150 kWh lithium battery + UPS system

Results:
– Energy independence during daytime (70% of consumption)
– Zero production stoppage due to power issues (99.95% uptime)
– Operating costs reduced by ₹1.5 crores/year
– Regulatory compliance: Met all ISO 50001 requirements
– Improved brand value for export markets

Investment: ₹1.75 crores
Payback Period: 1.9 years

Industrial Compliance & Standards

Certified, Compliant, and Safety-Approved Systems

Industry Standards Compliance:

IS/IEC 61730: Solar module safety standards
IS/IEC 61215: Performance standards for PV modules
National Electrical Code (NEC): Electrical installation safety
ISO 50001: Energy management system standard
OHSAS 18001: Occupational health and safety
BIS Certification: Bureau of Indian Standards approval
MSEDCL Technical Standards: Maharashtra electricity board specs

Factory Inspection & Certification:

Our installations include:

Third-party structural audit
Electrical safety inspection
Production capacity verification
Performance testing certification
Warranty documentation

Understanding Agricultural Water Needs

Calculating Your Farm's Water Requirements

Service	Frequency	Cost	Benefit
Equipment Inspection	Monthly	Included	Early issue detection
Panel Cleaning	Quarterly	₹10,000-20,00 0	Maintains 3-5% efficiency
Inverter Servicing	Bi-annually	₹8,000-15,000	Prevents downtime
Battery Health Check	Quarterly	₹5,000-10,000	Extends battery life
Full System Audit	Annually	₹20,000-30,00 0	Performance verification
Thermal Imaging	Annually	₹15,000-25,00 0	Identifies hot-spots

Preventive Maintenance Benefits:

Reduces unplanned downtime by 90%
Extends system lifespan to 30+ years
Maintains performance ratio above 80%
Prevents costly emergency repairs
Protects warranty validity

24/7 Support:

Dedicated industrial support team
Emergency response within 2 hours
Spare parts inventory maintained

● Certified technician network across region

Financing Options for Industrial Solar

Flexible Payment Options for Large Investments

Option	Terms	Advantage
Bank Financing	5-10 years, 8-10% interest	Traditional approach, CAPEX model
NBFC Loans	5-7 years, slightly higher rates	Faster approval, flexible terms
Equipment Leasing	5-8 years	Off-balance sheet (accounting benefit)
Hire Purchase	3-7 years	Eventual ownership with flexibility
Vendor Financing	3-5 years	Direct from equipment suppliers
Energy Service Company (ESCO)	5-7 years, performance-based	Pay from energy savings

ESCO Model Highlights:

ESCO installs and operates system
You pay monthly from energy savings generated
No upfront capital required
Risk transferred to ESCO
60-70% of generated savings retained by your business

Why Choose Raut Renewable Energy – Industrial Division

Trusted Partner for Large-Scale Industrial Solar

Industrial Expertise

35+ years in power supply, industrial operations experience

Large-Scale Capability

Successfully completed 50+ industrial projects (50 kW – 5 MW)

Technical Excellence

Team with power systems engineering background

Quality Equipment

Premium pumps and components for durability

24/7 Support

Dedicated industrial support division, emergency response

Performance Guarantee

SLA-backed generation guarantees

Financial Optimization

Expert in maximizing incentives and financing

Turnkey Solution

End-to-end from design through 25-year maintenance

Frequently Asked Questions

Will solar installation disrupt production?

No. Installation done during non-peak hours. Phased approach ensures zero production downtime. Parallel operation possible during transition.

Can I increase system capacity as production grows?

Yes. Most systems designed with expansion capability built-in. Adding capacity 3-5 years later is straightforward and cost-effective.

What happens during monsoon or cloudy days?

Production reduces 40-60% but doesn’t stop. Grid or battery acts as backup. No interruption to operations.

How do I get tax benefits?

Our financial consultants guide on accelerated depreciation, Section 80-IA benefits, and SCCL credits. Work with your CA for implementation.

Is battery storage necessary for 24/7 operations?

For 100% 24/7 independence, yes. Without battery, you need grid backup for nights/cloudy days. Hybrid system recommended.

Can I sell excess solar energy to neighbors?

Currently, selling directly to consumers not permitted. Excess goes to grid via net metering, credited to your account.

What if my facility has limited roof space?

Ground-mounted or canopy-mounted options available. Most industrial facilities have adequate ground space for large arrays.

How does net metering work for industrial facilities?

Excess solar generation sends to grid, credited to account. Most industrial consumption happens daytime (when solar generates), minimizing grid purchase.

What's the warranty on large systems?

25-year performance warranty on panels, 5-10 years on inverters/components. Extended warranties available on request.

Can I integrate solar with my existing power management systems?

Absolutely. Our SCADA integrates with PLCs, energy management systems, and facility management systems.