Commercial Solar Installation: Factory Case Study
How a Chittagong textile factory reduced electricity costs by 65% with 200kW solar installation. B2B case study with ROI breakdown.
The Challenge: Skyrocketing Electricity Costs
Located in the Chittagong Export Processing Zone, this mid-size textile factory was spending over BDT 25 lakh per month on electricity. With 12-hour production shifts, heavy machinery including looms, dyeing units, and climate control systems, electricity was the single largest operational expense — eating into profit margins already under pressure from global competition.
The factory management explored several options including diesel generators and energy efficiency upgrades before deciding that solar offered the best long-term solution.
System Design and Installation
Our engineering team designed a 200kW rooftop solar system tailored to the factory's specific requirements:
| Component | Specification | Quantity |
|---|---|---|
| Solar Panels | 550W Mono PERC (Tier-1) | 364 panels |
| Inverters | 50kW String Inverters | 4 units |
| Mounting | Industrial flush-mount rails | Full roof coverage |
| Monitoring | Cloud-based SCADA system | 1 system |
| Net Metering | Bi-directional CT meters | 1 set |
Installation Challenges and Solutions
The installation presented several unique challenges that our team successfully addressed:
- Structural assessment: The factory roof required reinforcement in two sections to support panel weight — completed without disrupting production
- Production continuity: Installation was phased over 3 weekends to minimize downtime, with electrical connections done during scheduled maintenance windows
- Monsoon planning: The system was designed with enhanced drainage channels and wind-resistant mounting to handle Chittagong's severe weather
- Grid compatibility: Coordination with BPDB Chittagong for 200kW net metering approval required specialized transformer and protection equipment
Results: 18 Months Post-Installation
The results exceeded initial projections:
| Metric | Before Solar | After Solar | Improvement |
|---|---|---|---|
| Monthly electricity bill | BDT 25,00,000 | BDT 8,75,000 | 65% reduction |
| Monthly savings | — | BDT 16,25,000 | — |
| Annual savings | — | BDT 1,95,00,000 | — |
| Carbon offset | — | 240 tons CO₂/year | — |
| System payback | — | 2.8 years | Expected 3.5 years |
Lessons for Other Manufacturers
This case study demonstrates that commercial solar installations in Bangladesh offer exceptional returns, particularly for energy-intensive manufacturing operations. The key success factors were proper system sizing based on actual load profiles, choosing a Tier-1 panel brand for long-term reliability, and working with an installer experienced in industrial-scale projects.
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