Technical Brief: 195 kWp Commercial Rooftop Solar Project – Pune, Maharashtra
Manufyn designed, installed, and commissioned a 195 kWp rooftop solar power plant for a live commercial building in Pune operating under a commercial HT connection. The project aimed to offset high grid electricity costs while ensuring uninterrupted daily operations and full compliance with HT electrical and DISCOM regulations.
Key Technical Highlights:
Engineering & Design: Detailed shadow analysis and generation simulations were conducted to optimize module placement on a space-constrained rooftop with existing obstructions. High-efficiency Tier-1 solar modules and optimized string design maximized energy yield per square meter.
HT Compliance & Execution: The project included complete HT safety integration—cubicles, transformer interfacing, AB switches, earthing, and fire safety systems. Phase-wise installation ensured zero disruption to building occupants.
Performance Outcome: The system generates ~23,400 units per month, delivering annual savings of ₹49+ lakhs and achieving an estimated payback of ~1.35 years, ensuring rapid ROI and long-term energy cost reduction.
How Manufyn delivered a high-capacity HT rooftop solar system with 1.35-year payback for a live commercial building
Project Overview
Manufyn successfully designed, installed, and commissioned a 195 kWp rooftop solar power plant for a commercial building in Pune, Maharashtra. The project was executed under a commercial HT electricity connection, enabling the client to significantly reduce electricity costs under the prevailing high-tariff structure.
The installation was carried out while the building remained fully operational during working hours, with strict adherence to safety, electrical, and DISCOM compliance requirements.
Project Details
| Parameter | Details |
|---|---|
| Project Type | Rooftop Solar Power Plant |
| Installed Capacity | 195 kWp |
| Client Category | Commercial Building |
| Location | Pune, Maharashtra |
| Execution Timeline | 90 Days |
| Connection Type | Commercial / HT |
Client Requirements
The client approached Manufyn with clearly defined objectives:
- Reduction in high electricity bills under the ₹17.63/unit MSEB tariff
- Quick installation without disrupting daily commercial operations
- Behind-the-meter compliance as per local DISCOM regulations
- Strict adherence to HT electrical safety norms, including cubicles, transformers, AB switches, earthing, and fire safety
Major Challenges
1. Limited Rooftop Space
The usable rooftop area was constrained due to existing HVAC units, water tanks, and billboards, limiting module placement options.
2. Shadow-Free Layout Optimization
Surrounding buildings and trees caused partial shading during certain hours, which required careful layout planning to avoid generation losses.
3. Live Building Execution
The project had to be executed while the commercial building remained fully operational, demanding high levels of safety coordination and phased execution during working hours.
Manufyn’s Engineering & Execution Approach
To address these challenges, Manufyn adopted a precision-driven, site-specific engineering approach:
- Conducted detailed shadow analysis and generation simulations to identify optimal module placement
- Optimized module orientation and string design to maximize output within the available rooftop area
- Deployed high-efficiency Tier-1 solar modules to achieve higher generation per square meter
- Planned phase-wise installation to avoid disruption to building occupants and daily operations
- Ensured complete compliance with HT electrical safety norms, including cubicle design, transformer interfacing, AB switch integration, earthing, and fire safety requirements
- Managed end-to-end DISCOM coordination, approvals, and behind-the-meter documentation
This approach ensured technical performance, safety compliance, and smooth execution in a live commercial environment.
Project Performance & Financial Impact
| Performance Metric | Value |
|---|---|
| Average Monthly Generation | ~23,400 units |
| Applicable MSEB Tariff | ₹17.63 / unit |
| Estimated Monthly Savings | ~₹4.1 lakhs |
| Estimated Annual Savings | ₹49+ lakhs |
| Payback Period | ~1.35 years |
The system significantly reduced the client’s dependency on high-cost grid power, delivering fast ROI and long-term energy security.
Client Feedback
“Manufyn delivered the project within the committed timeline while ensuring zero disruption to our operations. Their technical understanding of HT commercial connections and DISCOM coordination was exceptional.”
— Management Team, Pune
Lessons Learnt
(Practical Insights – Commercial HT Rooftop Solar in a Metro City)
- Early coordination with Maharashtra State Electricity Distribution Company helps reduce approval delays for HT consumers in metro cities, especially when infrastructure changes are involved
- Cable routing planning is critical in commercial buildings to avoid interference with existing services
- Phase-wise installation schedules are essential to maintain business continuity
- Regular coordination with facility managers ensures safety compliance during working hours
Manufyn vs Other Solar EPC Contractors
| Parameter | Manufyn | Typical EPC Contractors |
|---|---|---|
| Design Optimization | Site-specific & shadow-based | Standard layouts |
| HT & DISCOM Expertise | Strong | Limited |
| Component Quality | Tier-1 only | Mixed |
| Execution in Live Premises | Planned & safe | Risk-prone |
| Payback Optimization | High | Moderate |
| Post-Commissioning Support | Dedicated | Limited |
Why Manufyn for Commercial Rooftop Solar
- Proven expertise in commercial and HT rooftop solar projects
- Strong understanding of MSEDCL / MSEB regulations and approvals
- Faster ROI through optimized engineering and system design
- End-to-end EPC execution with long-term O&M support
Looking to reduce high commercial electricity costs in Pune or across Maharashtra?
Get clarity on savings, payback, and feasibility before you invest.
