How much solar can your factory actually install?
Three numbers decide it: your daytime consumption, your usable roof, and your DISCOM's rules. Everything else is arithmetic. Here's how we size factory solar — and what it costs when it's engineered honestly.
15+ years · 535+ projects · Design, approvals & execution in-house · ISO 9001:2015
Size to the smallest of three limits
Consumption limit
Your daytime base load sets the ceiling on what solar can offset without fighting banking rules. A plant bigger than your consumption exports at unfavourable rates — or gets curtailed. How we measure it →
Roof limit
Plan ~100 sq.ft of shadow-free roof per kW. Skylights, vents, parapets and shadows shrink the usable figure — and old structures need a verdict before design.
Rules limit
DISCOMs cap net-metered capacity against sanctioned load, and banking rules differ by state. Check your sanctioned-load headroom →
A ₹3 lakh/month factory, sized honestly
| Monthly bill | ₹3,00,000 (₹9/unit blended) |
| Consumption | ≈33,300 units/month |
| Solar to offset it | ≈275 kW |
| Shadow-free roof needed | ≈27,500 sq.ft |
| Indicative turnkey cost | ≈₹1.24 Cr |
| Est. monthly saving | ≈₹2.9 L/mo |
| Indicative payback | ≈3.6 yrs |
Same assumptions as our calculator (~120 units/kW/month, ₹40–50k/kW). Your tariff, roof and DISCOM shift every line — run yours.
Where factory solar goes wrong
- Sized to the roof, not the load — the #1 payback killer. Bigger is not better past your consumption.
- Winter honesty — North India's fog season cuts generation; models that ignore it overpromise by 8–12% annually.
- Structure skipped — panels on corroded purlins are a liability, not an asset.
- DG interlocks missing — solar that trips your changeover or back-feeds a DG is an integration failure, not bad luck.
- Vendor guarantees that guarantee nothing — what a PR guarantee must actually say.
Cost breakdowns by plant size
100 kW plant cost
The small-factory workhorse — LT-side, simplest approvals, fastest install.
500 kW plant cost
Mid-size manufacturing — HT considerations, transformer bay, string inverters at scale.
1 MW plant cost
Large plants — rooftop vs open access, banking limits, financing structures.
HT-connected plant with DG sets and heavy motor loads? Read Industrial Solar EPC — integration is its own discipline.
Factory solar questions, answered by engineers
How much solar does my factory need per lakh of monthly bill?
As a working figure at a ₹9/unit blended tariff, a ₹1 lakh monthly bill is roughly 11,000 units — about 90–95 kW of solar if you wanted to offset all of it, or less if your DISCOM caps net metering at your sanctioned load. Size against consumption and rules, not the bill alone; the calculator does this arithmetic for your numbers.
My factory runs 6 days a week. What happens to Sunday generation?
Under net metering it's exported and credited per your DISCOM's banking rules — which differ by state and are tightening in several. Under a captive/behind-the-meter design without export, Sunday generation is curtailed unless you shift load. This single policy detail changes optimal plant size by 10–20% and is exactly the kind of input an EPC should model before quoting.
Is my factory roof strong enough for solar?
Pre-engineered sheds usually take ~12–15 kg/m² of additional load comfortably, but older trussed roofs, corroded purlins and asbestos sheets need a structural verdict first. We survey before we design — replacing sheeting or reinforcing purlins is sometimes part of an honest quote, and skipping that check is how plants end up on roofs that can't hold them.
What does factory solar cost per kW?
Current C&I turnkey benchmarks run roughly ₹40,000–50,000 per kW installed for rooftop systems, varying with structure type, cable runs, inverter class and metering scope. See the detailed breakdowns for 100 kW, 500 kW and 1 MW plants, or run your own configuration in the calculator.
Does GST or depreciation change the economics?
Materially. Businesses can claim accelerated depreciation (40% WDV) on solar assets and input credit treatment depends on how the contract is structured — both improve post-tax payback versus the sticker calculation. We flag the current treatment during proposal; confirm specifics with your CA, as tax positions change.
Who handles the DISCOM paperwork and inspections?
We do, in-house — net-metering application, CEIG approval and synchronisation. Approvals are our core trade as an MEPF contractor; our published guide on net-metering timelines in UP, Punjab and Haryana reflects filings we actually run, not theory.
Send one electricity bill. Get an engineering answer.
WhatsApp a recent bill and two roof photos — an engineer replies with what your factory can realistically install, and whether it's worth doing.
Estimate your facility's solar savings
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