Case Study Detail

Engineering & Metal Unit, Tamil Nadu
1.5MW Pure Wind Turbine System

Tamil Nadu, India • Heavy Engineering & Metal Fabrication

System Capacity 1.5MW Wind
Monthly Bill Offset 55% Offset
Monthly Savings ~₹28.0 Lakhs / mo
Payback Period ~3.8 Years

Facility Overview

Located in Tamil Nadu, India, this heavy engineering plant manufactures precision metal castings and automotive structural components. Operating heavy induction furnaces, CNC machining centers, and stamping presses, the plant recorded a monthly grid electricity bill of ₹51 Lakhs.

The Challenge

  • Heavy Induction Furnace Loads: High inductive load surges created severe peak demand surcharges during shift changes.
  • Grid Power Quality Harmonics: Voltage sags on the utility grid tripped CNC machining centers, damaging precision tooling.
  • High Base Operating Costs: Utility power tariffs represented a significant portion of component unit manufacturing cost.

The Solution

OnLoop Energy deployed a 1.5MW Captive Wind Turbine System equipped with dynamic power quality conditioning filters.

  • 24/7 Wind Power Generation: Wind energy supplies stable base power for multi-shift metal forging lines.
  • Harmonics & Power Quality Filtering: Integrated active filters eliminate voltage sag trips on sensitive CNC machinery.
  • Peak Load Management: High capacity wind generation lowers overall grid dependence to ~45%.

Financial Breakdown & Performance

Turnkey System Investment ~₹12.0 Crores
Monthly Tariff Savings ~₹28.0 Lakhs / mo (55% Offset)
Annual Tariff Savings ~₹3.36 Crores / year
Estimated Payback Period ~3.8 Years
20-Year Lifetime Savings ~₹67 Crores