Installing solar rooftop systems for factory premises is one of the smartest ways for manufacturing units in Maharashtra to cut energy costs & move toward sustainability. Whether solar rooftop sytem on factory roofs, ground mounted systems in factory premise or open access solar plants, offer long-term savings and reliable clean power.
Choosing the right solar panels for a factory roof or a dedicated ground-mounted setup—goes beyond just panel selection. To fully benefit from solar power for factory operations, owners must plan carefully across policy compliance, engineering design, financing models, grid connectivity, and execution quality. By focusing on seven key considerations from site assessment & load analysis to system integration and maintenance, you can unlock the full potential of solar power for your factory, achieving both cost savings & sustainable growth.
Industrial energy costs are high and trending upward which makes solar rooftop for factory consumption an effective hedge. Average billing rate for HT industrial consumers is about ~₹9.20 per kWh in FY 2025–26 (source). By generating electricity on site with solar panels on factory roof areas, plants reduce grid dependence, stabilise energy budgets, and utilise otherwise idle roof real estate. Systems can materially lower electricity expenditure while supporting ESG commitments. Beyond direct savings, solar power for factory campuses improves energy security and resilience against tariff escalation or supply interruptions. These are the core reasons more manufacturers are adopting solar panels for factory integration as a long term asset. Maharashtra records about 250 to 300 sunny days and 4 to 6 kWh/m² daily solar radiation; a 1 MW rooftop typically yields about 1.5 million kWh per year (source).
GSE Renewables offers end-to-end solar solutions for industries, whether it’s rooftop solar to maximize factory roof space, ground-mounted plants for higher capacity, or open access solar through the grid. Our scalable, cost-efficient systems help factories cut power costs, boost sustainability & secure long-term energy savings.
Installing solar panels in Maharashtra calls for careful planning from assessing net metering eligibility and roof strength to understanding grid timelines, open access policies & local compliances. Selecting the right vendor and calculating ROI are key to maximizing savings and ensuring long-term energy security. Let’s explore these factors in detail.
Net metering enables a solar system for factory users to export surplus daytime generation to the grid and receive credits against import. Eligibility and capacity caps are defined by the DISCOM, and approvals typically require design submissions, safety certificates, and a bidirectional meter installation. When implemented, net metering strengthens cash flows by valuing excess kilowatt hours and utilize them during other parts of the day and shortens payback on the solar panel cost for factory projects.
Impact on ROI: By banking surplus generation and offsetting it in ToD wise consumption, it significantly improves the internal rate of return of a solar panel system for factory operations.
Installing solar panels on factory roof structures is an engineering task, not merely a space exercise. Commission a structural audit to verify purlin spacing, truss integrity, corrosion, roof age, and allowable distributed load. Conventional modules with mounting add roughly 20 to 30 kilograms per square metre. Wind uplift and seismic loads also require attention. Older asbestos or lightweight sheet roofs may need reinforcement or alternative technologies.
Good practice
A sound roof strategy protects assets, workers, and production continuity while supporting the longevity of solar panels for factory roofs.
From engineering to commissioning, timelines combine site works and approvals. Installation may finish in weeks, but utility steps such as inspections, agreements, and meter provisioning commonly add 60 to 90 days for rooftop projects. For open access or captive projects above 1 megawatt, land, evacuation studies, SLDC coordination, and metering can extend schedules to several months.
Key steps
Ways to accelerate: Submit complete drawings, plan inspections early, and work with an EPC familiar with your DISCOM so the solar power for factory asset reaches commissioning without idle time.
If your factory has very large power requirements, you should also understand the option of open access solar power. Open access allows industrial consumers to buy electricity directly from a solar farm or independent power producer, rather than installing all generation on-site. In Maharashtra, open access is typically available to consumers with a contract demand of 1 MW or more. It’s governed by MERC’s Green Energy Open Access rules, which let eligible businesses purchase renewable power on the open market.
The open access model is suited for factories that cannot meet their entire consumption through rooftop panels alone (due to limited roof area or enormous energy needs). Under open access, a dedicated solar plant for factory consumption is set up off-site, often a large utility-scale solar park and the power is transmitted via the grid to your facility. For example, a company could invest in or contract power from a 5 MW solar farm in a sunny part of Maharashtra and receive that energy at its factory through the utility network. This setup allows scaling to much higher capacities than a rooftop system, achieving economies of scale.
There are a few models to procure solar open access mode are listed as follow:
If your factory’s consumption is very high and a rooftop solar system for factory usage can only supply a fraction of it, open access may be worthwhile to source additional green power. It is generally recommended when your energy demand consistently exceeds what ~1 MW of solar can produce, or if you have multiple facilities and want a centralized solar supply. Open access can offer cost advantages too; large solar farms often produce power at a lower unit cost. Factories can lock into long-term stable tariffs (e.g. 10-15 year PPAs) that are lower than prevailing industrial grid rates, providing a hedge against future tariff hikes. However, keep in mind the open access framework has detailed regulations and prerequisites (such as the 1 MW minimum demand, SLDC scheduling, special metering, etc.), so it involves more complexity than a simple rooftop project
Robust compliance underpins safe and legal operation of solar panels for factory projects.
Choosing a trusted solar EPC company for factory roof installations is essential to maximize efficiency, safety, and long-term performance of your solar power system. Here are the key factors to consider before selecting your solar installation partner.
A successful solar panel installation balances initial capital costs with long-term savings & potential risks. The following points provide a clear framework to evaluate the cost of installing a solar panel system for factory operations.
| Parameter | Details |
|---|---|
| Capacity | 1,000 kW solar rooftop system for factory |
| Capital | About ₹3.5–4.0 crore |
| Annual Generation | About 1.3–1.4 million kWh per year |
| Tariff Offset (Assumed) | ₹8 per kWh |
| Gross Annual Savings | About ₹1.1 crore |
| O&M Cost | About ₹5–6 lakh per year |
| Simple Payback | About 3.5–4 years |
Note: Figures are illustrative and will vary with site conditions, component selection, and tariff structure.
Use our Solar Calculator to quantify the business case for a solar panel system for factory sites in Maharashtra. Adjust capacity, tariff, consumption profile, and policy inputs such as net metering to view savings, payback, and IRR with clear assumptions. Compare rooftop only versus mixed rooftop and ground or open access scenarios to select the most effective configuration.
Installing solar panels for factories in Maharashtra is a strategic step toward reducing energy costs & achieving sustainability. By understanding net metering rules, grid timelines, roof capacity, open access options, compliance needs, vendor selection & ROI, factories can make informed decisions that allow them to get more energy output & savings. Partnering with an experienced solar EPC company ensures a smooth execution & long-term reliability. We help industries to consider these factors to design efficient, compliant & cost-effective solar panel solutions for their factory needs.
DISCOM interconnection and net metering where applicable, Electrical Inspectorate safety clearance, structural NOCs for solar panels on factory roof installations, and compliance with fire safety and electrical standards.
Rooftop projects typically commission in a few months, with utility approvals often setting the critical path. Larger open access solar plant for factory projects require additional months for grid studies and metering.
Quality modules carry 25 year performance warranties. With routine operations and maintenance, solar power for factory assets can operate productively for 25 to 30 years, with periodic inverter replacement.
Not every factory roof is suitable for solar panels. Factors like roof strength, load-bearing capacity, orientation, shading & available surface area determine feasibility. Before installation, a structural assessment and site survey are essential to ensure safety, efficiency & compliance.
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