Technical Brief: Industrial Rooftop Solar Power Plant – Pune, Maharashtra
Manufyn engineered, installed, and commissioned a 67.71 kWp industrial rooftop solar power plant at a live manufacturing facility in MIDC, Pune, without interrupting plant operations. The project was designed to offset high LT commercial electricity costs while meeting strict safety, net-metering, and DISCOM compliance requirements.
Key Technical Highlights:
Engineering & Design: Detailed shadow analysis and generation simulations were performed to optimize module placement on a space-constrained RCC rooftop with existing obstructions. High-efficiency Tier-1 modules and a SolarEdge 3rd-generation inverter were selected to maximize energy yield per square meter.
Execution Strategy: Installation was carried out in planned phases to ensure zero downtime, with a fabricated tin-shed mounting structure designed for wind load and long-term durability.
Regulatory & Performance Outcome: End-to-end MSEDCL coordination enabled smooth LT net-metering approval. The system generates ~8,125 units monthly, delivering ~₹10 lakh annual savings and an estimated ~2-year payback, ensuring rapid ROI and long-term cost reduction.
How Manufyn delivered a zero-downtime rooftop solar installation with ~2-year payback for a live industrial facility
Project Overview
Manufyn successfully designed, installed, and commissioned a 67.71 kWp industrial rooftop solar power plant at an operational manufacturing facility in MIDC, Pune, Maharashtra. The project was executed on a live plant operating under an LT commercial electricity connection, with zero production downtime throughout installation.
The objective was to reduce high electricity costs under the prevailing Maharashtra State Electricity Distribution Company tariff, while ensuring strict compliance with safety, net metering, and industrial LT norms.
Project Details
| Parameter | Details |
|---|---|
| Project Type | Rooftop Solar Power Plant |
| Installed Capacity | 67.71 kWp |
| Client Category | Industrial |
| Location | Pune, Maharashtra |
| Execution Timeline | 90 Days |
| Connection Type | Industrial / LT |
Client Requirements
The client approached Manufyn with clearly defined objectives:
- Significant reduction in high electricity bills under the ₹10.24/unit MSEDCL tariff
- Installation of a tin shed with fabricated mounting structure on an RCC rooftop
- Fast execution without interrupting daily plant operations
- Net metering compliance as per local DISCOM regulations
- Strict adherence to electrical safety standards under LT norms
Major Challenges
1. Limited Rooftop Space
The usable rooftop area was restricted due to existing HVAC units, overhead water tanks, and a mobile tower. This significantly constrained module placement and layout options.
2. Shadow-Free Layout Optimization
Nearby buildings and trees caused partial shading during certain hours, which could negatively impact energy generation if not addressed through proper design.
3. Live Plant Execution
The solar installation had to be carried out while the plant remained fully operational, requiring detailed safety planning, phased execution, and coordination with plant personnel.
Manufyn’s Engineering & Execution Approach
To overcome 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 configuration using a SolarEdge 3rd-generation inverter to maximize energy yield in a space-constrained layout
- Deployed high-efficiency Tier-1 solar modules to achieve higher generation per square meter
- Executed installation in planned phases to ensure plant operations were not disrupted
- Managed end-to-end DISCOM coordination, including approvals, documentation, and net metering compliance
This approach ensured both technical performance and smooth execution in a live industrial environment.
Project Performance & Financial Impact
| Performance Metric | Value |
|---|---|
| Average Monthly Generation | ~8,125 units |
| Applicable MSEDCL Tariff | ₹10.24 / unit |
| Estimated Monthly Savings | ~₹0.83 lakh |
| Estimated Annual Savings | ~₹10 lakh |
| Payback Period | ~2 years |
The system substantially reduced the client’s dependency on high-cost grid electricity, delivering rapid ROI and long-term operational savings.
Client Feedback
“Manufyn’s team handled the entire project very professionally. Despite space limitations and a running plant, the installation was completed safely and on time. Our electricity bills have reduced drastically, and the performance of the system has exceeded expectations.”
— Director
Lessons Learnt
(Industrial LT Rooftop – MIDC, Pune)
- Accurate shadow analysis is critical for industrial rooftops with surrounding obstructions
- High-efficiency modules combined with module-level optimization and 3rd-generation inverters significantly improve output in space-constrained sites
- Phase-wise execution planning is essential when working in live industrial environments
- Early coordination with MSEDCL helps avoid delays in net metering approvals
Tin shed and fabricated structures must be designed considering wind load and long-term durability
Manufyn vs Other Solar EPC Contractors
| Parameter | Manufyn | Typical EPC Contractors |
|---|---|---|
| Design Optimization | Site-specific & shadow-based | Standard layouts |
| HT / LT & 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 industrial HT & LT rooftop solar projects
- Strong understanding of MSEDCL regulations and approvals
- Faster ROI through optimized engineering and layout design
End-to-end EPC execution with long-term O&M support
Looking to reduce high commercial electricity costs in Pune or across Maharashtra?
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