Case Study Detail
Textile & Dyeing Unit, Surat
1.2MW Wind-Solar Hybrid System
Surat, India • Textile Processing & Dyeing Industry
System Capacity 1.2MW Hybrid
Monthly Bill Offset 70% Offset
Monthly Savings ~₹17.50 Lakhs / mo
Payback Period ~3.2 Years
Facility Overview
The facility is a leading high-capacity textile dyeing and fabric processing mill operating out of Surat, India. Running continuous 24/7 production cycles, the mill consumes high utility power across dyeing jets, stenters, and boilers with an average baseline monthly electricity bill of ₹25 Lakhs.
The Challenge
- Continuous 24/7 Dyeing Cycles: Stenter machines and dyeing jets operate on non-stop shifts, driving high utility grid bills during expensive night hours.
- High Night-Shift Grid Tariffs: Time-of-Day (TOD) night surcharges severely eroded operating profit margins on fabric processing.
- Unscheduled Grid Interruptions: Sudden industrial grid outages ruined chemical dyeing batch quality, resulting in costly material re-dyeing.
The Solution
OnLoop Energy conducted a comprehensive 3-phase load curve audit and engineered a 1.2MW Wind-Solar Hybrid System designed specifically for the mill's diurnal power demand.
- Captive Wind Turbines: Direct-drive turbines provide continuous power 24/7, covering night dyeing jet loads.
- Daytime Solar Generation: Rooftop solar array covers peak daytime thermal and processing machinery loads.
- Smart Power Integration: Battery storage buffer ensures zero dropouts during grid trips, securing chemical batch stability.
Before vs After Performance
Financial Breakdown & ROI
Turnkey System Investment ~₹7.2 Crores
Annual Tariff Savings ~₹2.10 Crores / year
Estimated Payback Period ~3.2 Years
20-Year Lifetime Savings ~₹42 Crores