Ceramics & Tiles Plant, Morbi
2MW Wind-Solar Hybrid System

Facility Overview

Located in Morbi, India — one of the world's largest ceramics production clusters — this manufacturing facility produces large-format vitrified floor tiles. Running continuous 24/7 roller kilns that cannot be shut down without incurring severe thermal loss, the plant operated with a baseline monthly utility power bill of ₹43 Lakhs.

The Challenge

• 24/7 Kiln Operation: Continuous roller kilns require unbroken power draw around the clock; thermal loss from power stops damages kilns.
• Severe Peak Demand Penalties: High-voltage grid connections incurred heavy Maximum Demand (MD) surcharges during peak hours.
• High Night Shift Electricity Costs: Heavy thermal firing cycles during night shifts suffered high grid utility tariffs.
• Zero Protection Against Outages: Unscheduled grid trips interrupted production lines and ruined raw batch materials.

The Solution

OnLoop Energy designed and installed a 2MW Wind-Solar Hybrid System customized to shave peak demand penalties and offset night kiln firing cycles.

• Captive Wind Turbines: Provides 24/7 continuous power for non-stop roller kiln operations.
• Daytime Solar Generation: Offsets daytime peak heating demand and auxiliary fan loads.
• Peak Demand Shaving: Hybrid architecture smooths peak MD spikes, protecting the plant from grid penalty fees.

Before vs After Performance

Financial Breakdown & ROI