A Gujarat foundry wanted to cut one of its biggest running costs: grid electricity. Renesys built two 4.5 MWp ground-mount captive solar plants in North Gujarat and has run both since commissioning. Together they generated 13.25 million units in FY 2025-26.
The challenge
A foundry uses a lot of power, and there was no room for a plant of the right size at the factory. The solar had to be built on land far away, in North Gujarat, and the power sent to the factory over the grid.
That means registering with GEDA, getting GETCO technical feasibility, setting up the DISCOM estimate and wheeling, getting Chief Electrical Inspector clearance, and building a dedicated 11 kV line to a GETCO substation for each plant.
What we delivered
Two plants, two phases
The first 4.5 MWp plant was commissioned in March 2022 and feeds a 66 kV GETCO substation through its own 11 kV line. The client came back to us for a second 4.5 MWp plant, commissioned in June 2024.
Grid connection
Each plant has a dedicated 11 kV feeder, and the second plant has 3.5 km of 11 kV underground XLPE cable. Both have ABT export/import metering.
Every approval, handled
GEDA registration, GETCO feasibility, DISCOM connectivity and wheeling, and the Chief Electrical Inspector’s inspection and charging permission.
Quality equipment
540 Wp bifacial modules from a Tier-1 Indian maker, with the plant designed for high year-round yield in North Gujarat.
Performance under Renesys O&M
FY 2025-26: our site team logged and monitored both plants on 361 days of the year, covering daily generation, meter readings, irradiance and every fault event.
| Metric | Plant 1 · 2022 | Plant 2 · 2024 |
|---|---|---|
| Units generated | 6.09 million kWh | 7.16 million kWh |
| Performance ratio | 78.0% with grid-failure days removed and adjusted for module ageing | 83.9% with grid-failure days removed |
CO₂ avoided is calculated with CEA’s grid emission factor of about 0.71 tCO₂/MWh.
O&M that protects generation
- Scheduled module cleaning to keep dust losses down through the dry season.
- Repairs at string level: faulty MC4 connectors, cables and junction-box fuses replaced, so no string stays offline.
- Switchgear failure fixed quickly: when the main 11 kV switch at Plant 1 failed in the 2025 monsoon, we diagnosed it, coordinated the repair and restored the plant fully.
- Tilt-angle correction at Plant 1, so the modules catch more sunlight.
- Handling grid trips: most of the year’s lost generation came from the grid, not the plant, and we managed every trip.
- Clear annual reporting that separates losses we can control from outside ones, such as grid failures and load-shedding.
Two plants, one partner. For an industrial buyer, solar only pays off when the plant keeps producing, year after year. That’s the job we’re paid to do.
Planning captive solar for your factory?
Ground-mount or rooftop, we’ll assess your land, load and approvals route.