Plastic Unit Production Cost Reduction
The Challenge
A plastic manufacturing unit in Pune running high-tonnage injection molding machinery suffered from extremely volatile electrical loads. Injection molding machines draw high starting currents and consume massive amounts of power during heating cycles, leading to high maximum demand charges from the utility. This high production energy cost directly ate into their profit margins on finished plastic goods.
The Solution
We installed a high-performance 500 kWp solar plant designed specifically to handle heavy starting currents and load spikes. Using cutting-edge string inverters with fast dynamic response times, the solar generation is synchronized to offset the high machinery load dynamically in real-time. Power factor correction equipment was also integrated to ensure zero penalties from the utility.
The Results & ROI
The solar installation successfully reduced the unit's daytime production electricity costs by 70%, yielding an annual saving of ₹42 Lakhs. This massive overhead reduction allowed the manufacturer to offer competitive wholesale pricing, improving their market share and product margins. The capital investment achieved a swift payback in 2.9 years, boosted by accelerated depreciation benefits.
"Transitioning this site to solar was not just about instant utility cost savings, but securing stable operational overheads against tariff inflation for the next two decades."
— SOLEV Project Operations Team
