Technical Brief: 200 kWp Industrial Rooftop Solar Project – Pune, Maharashtra
Manufyn successfully engineered and commissioned a 200 kWp rooftop solar power plant for an industrial HT consumer in Pune, Maharashtra. The project was designed to reduce high grid electricity costs, improve power reliability, and integrate with existing DG infrastructure. The objective was to deploy a high-efficiency solar system capable of delivering strong financial returns while operating seamlessly within a live industrial facility.
Key Technical Highlights:
HT-Compliant System Design:
The solar plant was designed specifically for an industrial HT connection, ensuring full compliance with transformer integration, cubicle requirements, AB switch installation, earthing systems, and DISCOM regulations. Net-metering integration was implemented to enable efficient energy export and billing alignment with Maharashtra State Electricity Distribution Company Limited.
High-Efficiency Component Selection:
The system utilized Tier-1 Waaree bifacial solar modules combined with 3rd generation SolarEdge inverters, enabling higher energy yield, module-level optimization, and improved generation performance compared to conventional systems.
DG Synchronization Capability:
The solar plant was engineered to support DG synchronization, allowing the system to operate efficiently during grid outages while maintaining electrical safety and system stability within the facility’s existing infrastructure.
Non-Invasive Rooftop Installation:
A specially designed leak-proof mounting structure was deployed to ensure installation without damaging the industrial rooftop waterproofing, preserving long-term structural integrity.
Phased Execution in Live Industrial Facility:
Installation was carried out through a structured phased deployment approach to avoid disruption to ongoing manufacturing operations. Strict safety protocols and coordinated site planning ensured uninterrupted plant activity throughout the 90-day execution period.
Outcome:
The system generates approximately 23,400 units of electricity per month, delivering estimated savings of ₹49+ lakhs annually at the prevailing tariff of ₹10.50/unit. With optimized engineering and high-efficiency components, the project achieved an estimated payback period of ~1.57 years, significantly reducing the client’s electricity expenditure while supporting long-term sustainability goals.
How Manufyn delivered a high-performance rooftop solar system with DG synchronization and ~1.57-year payback
Project Overview
Manufyn successfully designed and commissioned a 200 kWp rooftop solar power plant for an industrial client in Pune, Maharashtra. The system was installed under an HT (High Tension) connection, enabling the client to significantly reduce electricity expenses while improving power reliability.
In addition to lowering grid power consumption, the system was engineered to support DG synchronization during power shutdowns and provide carbon credit benefits, contributing to both operational cost savings and sustainability goals.
Project Details
| Parameter | Details |
|---|---|
| Project Type | Rooftop Solar Power Plant |
| Installed Capacity | 200 kWp |
| Client Category | Industrial (HT Consumer) |
| Location | Pune, Maharashtra |
| Execution Timeline | 90 Days |
| Connection Type | Industrial / HT (Net-Meter) |
Client Requirements
The industrial client approached Manufyn with specific technical and financial objectives:
- Reduction in high electricity bills under the prevailing ₹10.50/unit tariff from Maharashtra State Electricity Distribution Company Limited
- Integration of DG synchronization due to frequent electricity shutdowns
- Use of Waaree highest watt peak bifacial solar modules
- Deployment of 3rd generation SolarEdge Technologies inverters for optimized energy generation
- Targeted project payback within two years
- Quick installation without disrupting daily plant operations
- Net-metering compliance aligned with local DISCOM regulations
Major Challenges
1. Leak-Proof Rooftop Installation
Industrial rooftops required non-invasive mounting structures to prevent waterproofing damage and eliminate the risk of long-term leakage.
2. Live Plant Execution
The manufacturing facility remained fully operational throughout the project. This required:
- High-level safety coordination
- Phased installation planning
- Zero disruption to industrial operations
3. HT Infrastructure Integration
The project required careful integration with existing electrical infrastructure, including:
- Addition of an AB switch and DG synchronization
- Compliance with transformer and cubicle requirements
- Timely DISCOM approvals for infrastructure modifications
Manufyn’s Engineering & Execution Approach
To address these technical challenges, Manufyn implemented a precision-driven engineering and execution model.
- Conducted detailed shadow analysis and generation simulations
- Optimized module orientation and string design for maximum energy yield
- Installed high-efficiency Tier-1 bifacial solar modules for improved generation performance
- Executed installation through structured phased planning to avoid operational disruptions
- Ensured full HT electrical compliance, including cubicle integration, transformer interfacing, AB switch installation, earthing systems, and fire safety norms
- Managed complete DISCOM coordination, approvals, and documentation
This integrated approach ensured reliable system performance and smooth execution in a live industrial environment.
Project Performance & Financial Impact
| Parameter | Performance |
|---|---|
| Monthly Energy Generation | ~23,400 Units |
| Grid Tariff | ₹10.50 / unit |
| Estimated Monthly Savings | ₹4.1 Lakhs |
| Estimated Annual Savings | ₹49+ Lakhs |
| Payback Period | ~1.57 Years |
The system significantly reduced dependency on high-cost grid electricity while achieving faster-than-expected return on investment.
Client Feedback
“Manufyn delivered the project within the committed timeline and with high quality. The generation achieved is higher than the committed values, which has helped reduce our payback period even further, even after using Waaree bifacial solar modules and SolarEdge inverters.”
— Management Team, Pune
Lessons Learnt – Industrial HT Rooftop (Metro Execution Insights)
- Early coordination with Maharashtra State Electricity Distribution Company Limited helps reduce approval delays
- Proper cable routing planning prevents interference with existing utilities
- Phased installation ensures uninterrupted industrial operations
- Close coordination with facility managers improves on-site safety compliance
Manufyn vs Typical Solar EPC Contractors
| Parameter | Manufyn | Typical EPC |
|---|---|---|
| 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 Industrial Rooftop Solar
- Proven expertise in commercial and HT rooftop solar projects
- Strong understanding of Maharashtra DISCOM processes and approvals
- Faster ROI through optimized engineering and system design
- End-to-end EPC execution from design to commissioning
- Flexible financing options through NBFC partnerships, enabling monthly instalments lower than existing electricity bills and positive cash flow from day one
- Long-term operation and maintenance (O&M) support
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