Solar for auto component manufacturers in Gujarat
For a castings, forging or machining plant, power is one of the few big costs you can actually control. Renesys designs, builds and maintains rooftop and captive solar for auto component makers across Gujarat, so you pay less for every part you make and have real green-energy numbers when your OEM customers ask.
The power problem for auto plants
Induction furnaces, CNC lines, compressors and heat treatment run through the working day. In Gujarat, most HT plants pay roughly ₹7.50–8.50 per unit once energy charges, FPPPA, demand charges and duty are added up, and the FPPPA part keeps moving.
There is also a second pressure. Car makers now count the emissions in their supply chain, and suppliers are increasingly asked how much power they use and how they are cutting it. A plant that runs on a real share of solar has a better answer when that question comes.
Why solar fits auto plants
Your load runs by day
Machining and casting shifts overlap with solar hours, so almost all of the solar power is used inside your plant instead of going back to the grid.
Big, simple roofs
Press shops, assembly bays and warehouses usually have large sheet roofs that suit plants of 500 kWp to 1 MWp or more.
Captive when the roof isn’t enough
Foundries and forging units often need more power than a roof can produce. A ground-mount captive plant on land elsewhere, or a share in a group captive plant, covers the rest.
Numbers your OEM can use
You get monthly generation and self-consumption data your sustainability team can put straight into customer questionnaires.
Proof: 5 MWp captive plant for a steel-castings maker
A steel-castings manufacturer in Bhavnagar district, supplying the automotive and heavy-engineering sectors, wanted to cut its grid bill at scale. Its factory roof could not hold a plant of the right size, so Renesys built one on leased land and wheels the power to the factory through the grid.
| Capacity | 5 MWp DC / 4 MW AC, ground-mount on leased land |
| Model | Captive, with power wheeled through the DISCOM to the factory |
| Grid connection | Dedicated 11 kV line to a GETCO substation |
| Commissioned | March 2024 |
| Design output | About 82 lakh units a year |
| Renesys scope | Land development, EPC, approvals, grid connection and O&M |
| Repeat business | 1.5 MWp expansion under execution on the same site, due for commissioning by December 2026 |
The expansion reuses the land, roads, fencing, security and control room already built for the first plant, which lowers its cost per kWp.
More work in this sector
- 9 MWp captive solar for a ferrous-castings maker: two ground-mount plants that generated 13.25 million units in FY 2025-26. Read the case study →
- 895 kWp rooftop plant for an automotive components manufacturer, commissioned in 2024.
What we plan for in auto plants
- Foundry dust: a cleaning schedule based on how fast dust settles on your site, not a fixed calendar.
- Old shed roofs: a structural check of purlins and sheets before design, with replacement or reinforcement where needed.
- No production stoppage: installation is planned around your shifts, with short, scheduled switchover windows.
- Reporting you can hand to an OEM: monthly generation and self-consumption figures.
What it could save
A 1 MWp rooftop plant in Gujarat produces around 14.5 lakh units a year. If most of that replaces grid power at ₹7.50 or more per unit, it takes over ₹1 crore a year off your power bill, with a typical payback of 3–5 years.
Illustrative figures. Your actual saving depends on your tariff, load pattern and roof. We work it out from your last 12 months of bills.
Frequently asked questions
Can a three-shift plant still benefit from solar?
Yes. Solar covers your daytime load, which is usually the bulk of it in a machining or casting plant. The larger your daytime load, the more of the solar output you use yourself.
Our roof isn’t big enough. What are the options?
A ground-mount captive plant on land elsewhere, or group captive, where you take part-ownership of a shared plant. In both cases the power reaches your meter through the grid. Under Gujarat’s policy, captive plants don’t pay cross-subsidy or additional surcharge.
Will solar help with OEM sustainability questionnaires?
Yes. Solar gives you metered renewable units you can report, and we supply monthly generation data in a form your team can use.
How long does installation take?
A rooftop plant of around 1 MWp typically takes a few weeks to install, then goes live once approvals are through. Ground-mount captive takes longer because of land and grid work.
Who looks after the plant after commissioning?
We do, under an O&M contract that covers cleaning, monitoring, repairs and an annual performance report.
See if solar works for your plant
Send us your last 12 months of power bills. We’ll come back with a size, a saving and a payback estimate.