Phase Wise Installation saves Pharma Giant Crores & helps give back 23,000 trees to the Environment

Size: 196.2 KW solar power system

Components: 

Phase 1: 350 Wp Mono PERC Panels (38), ground mount structure

Phase 2: 390 Wp Mono PERC Panels (156), 

Phase 3: 445 Wp Mono PERC Panels (293), 100 KW inverter

Completion date: Phase 1: September 2020, Phase 2: November 2021, Phase 3: June 2022 

Verna Industrial Area in Goa is the manufacturing hub for some of the world’s largest research-based pharmaceutical companies. Ranking in the Fortune 100 list, the manufacturing unit of this particular pharma company manufactures medicines for several use cases and adheres to stringent compliance guidelines laid out by the Environment, Health, and Safety (EHS) department. It is one of the pioneering industrial brands to have considered phase-wise installation of their solar power plant.

Team SUN360 got an opportunity to be associated with the manufacturing unit from the period 2020 to 2022 during which multiple grid – tie solar power systems were executed in a phased manner –  first in April 2020, then in October 2021, and May 2022 wherein Waaree Mono PERC solar panels of 350, 380, and 445 Wattage were installed respectively.  

Even though the manufacturing unit budgeted this project under their capital expenditures, the phase wise installation works incredibly well because 

• The first phase kicked off in 2019 when the company installed 350 Wp solar panels in a small pilot project. SUN360 was contracted in April 2020 to augment the existing system with 350 Watt solar panels and install a new plant using higher efficiency 380Wp solar panels. In October 2021, Sun360 was commissioned to install another plant with 445Wp Mono perc solar panels. As is evident, the company leveraged the advent of higher efficiency solar panels to generate more power from a smaller area. The decision to adopt a systematic phase wise approach resulted in the company saving an area of 156 sq mtrs.

• Cost of deploying solar power plants has dropped significantly over the years. By deploying solar in a systematic phase wise manner the company has leveraged the falling solar prices. From April 2020 to October 2021, the company was able to benefit from a decrease in project cost of 13.07%

• The company was aware that technology would continue to improve and prices would continue to fall but still took a decision to go ahead with the installation of the first phase in 2019 because:

1. Installing the pilot project would give the management confidence on the savings accrued due to the solar power plant which would pave the way for larger deployment in the future.
2. Annual savings of Rs. 5.4 lakhs was possible in 2019. A rupee saved today is better than a rupee saved tomorrow (time value of money).
3. Installing the pilot project gave the project team experience that could be useful for future deployment of solar and eventual decarbonization of the company’s manufacturing activities.

What is noteworthy is that although the solar power plants were installed in different phases, the output is integrated into the distribution network of the company. Today, the pharma giant has a total installed capacity of over 500 KW, & the annual carbon dioxide emission reduction by this unit is equivalent to planting 23,000 trees. 

The back-up plan: 

The manufacturing unit has a Diesel Generator (DG), which provides backup power in case of grid failure. SUN360 has engineered the solar power system to include a PV DG synchronization system that ensures the solar inverter generates power according to the connected load in case of no grid. There is a smart distribution of the total load between the DG and the solar power plant such that the DG runs at a minimal load and the solar power plant fulfills the remaining demand. 

Team SUN360 is happy to have moved a needle towards the company’s efforts to create cost effective sustainable infrastructure for future growth & expansion, while setting a great example for sustainable development to the neighboring industrial units.