Industrial Solar EPC Case Study | Zero Roof Penetration Solar Installation
Project Overview
Client: Kompress India Pvt. Ltd.
Project Type: Industrial Rooftop Solar Power Plant
System Capacity: 120 kWp
Location: Maharashtra
Solar Modules: 600 Wp TOPCon modules
Inverters: Solis string inverters
Mounting Structure: Zero roof penetration mounting system
Grid Integration: Net metering
EPC Partner: VEMCO Solar, the renewable energy arm of Vijay Engineering & Machinery Pvt. Ltd. (VEMPL)
Project Background
Rising electricity costs are a major operating expense for industrial and manufacturing facilities. For businesses with significant daytime power consumption, rooftop solar can help reduce dependence on grid electricity while making productive use of available roof space.
Kompress India Pvt. Ltd., a manufacturer of storage and material handling systems, was looking for a rooftop solar solution that could reduce its electricity costs while addressing an important site-specific concern: the installation had to be completed without drilling or penetrating the existing roof.
VEMCO Solar developed and executed a 120 kWp industrial rooftop solar power plant designed around the client’s energy requirements and roof protection considerations.
The Challenge
The project involved three key requirements:
1. Reducing Industrial Electricity Costs
The client wanted to reduce its dependence on grid electricity and lower its recurring power expenditure through on-site renewable energy generation.
2. Making Effective Use of Existing Roof Space
The available industrial rooftop provided an opportunity for solar generation without requiring additional land or major changes to the facility.
3. Avoiding Roof Penetration
One of the key technical considerations was the client’s concern regarding potential roof leakage. Conventional mounting methods involving roof penetration were therefore not preferred.
The solar mounting solution needed to provide adequate structural stability while avoiding unnecessary drilling into the roof.
Our Solar EPC Solution
VEMCO Solar designed and executed a 120 kWp rooftop solar power plant incorporating high-efficiency components and a roof-friendly mounting approach.
600 Wp TOPCon Solar Modules
The project uses 600 Wp TOPCon solar modules, providing high module efficiency while making effective use of the available rooftop area.
Solis String Inverters
Solis string inverters were selected for the project to efficiently convert the DC power generated by the solar modules into AC power suitable for the facility’s electrical system.
Zero Roof Penetration Mounting Structure
A major feature of the project was the use of a zero roof penetration mounting structure.
The mounting approach was designed to avoid drilling into the roof, addressing the client’s concern about potential roof damage and water leakage while allowing the rooftop to be utilized for solar generation.
Net Metering Integration
The solar plant was integrated with the electrical system through net metering, enabling the facility to utilize solar power generated on-site and manage surplus generation in accordance with the applicable grid arrangement.
Project Results
The commissioned solar plant has helped the facility reduce its reliance on grid electricity.
Key Outcomes
- 120 kWp installed rooftop solar capacity
- Approximately 50% reduction in grid electricity consumption
- Significant reduction in monthly electricity expenditure
- No roof penetration for the solar mounting system
- Improved utilization of existing industrial rooftop space
- Reduced dependence on conventional grid electricity
- Contribution towards the facility’s sustainability objectives
The project demonstrates how an appropriately designed industrial rooftop solar power plant can address both energy-cost reduction and site-specific installation constraints.
Why Zero Roof Penetration Matters for Industrial Rooftop Solar
For industrial facilities, roof integrity is an important consideration when installing solar panels. Unplanned drilling or penetration can create potential points for water ingress and may affect the long-term performance of the roof system.
A zero roof penetration solar mounting solution can therefore be considered where maintaining roof integrity is a key project requirement, subject to structural assessment and site-specific engineering conditions.
For this project, VEMCO Solar incorporated the client’s roof protection requirement into the solar plant design rather than treating it as a separate installation constraint.
VEMCO Solar’s Approach
As the renewable energy arm of Vijay Engineering & Machinery Pvt. Ltd. (VEMPL), VEMCO Solar provides end-to-end solar EPC solutions for commercial and industrial facilities.
Our approach covers the complete project lifecycle, including:
- Site assessment and feasibility
- Rooftop and ground-mounted solar planning
- Solar capacity estimation
- System sizing and generation assessment
- Electrical and engineering design
- Module and inverter selection
- Mounting structure planning
- Solar EPC execution
- Grid and net metering coordination
- Performance monitoring
- Operation and maintenance support
Each project is evaluated based on the client’s energy consumption, available space, electrical infrastructure, roof characteristics and project objectives.
Project Takeaway
The Kompress India project demonstrates that industrial facilities can adopt rooftop solar while addressing practical site requirements such as roof protection, available space and electricity cost reduction.
With a 120 kWp rooftop solar plant, high-efficiency TOPCon modules, Solis string inverters and a zero roof penetration mounting system, the project combines renewable energy generation with a roof-conscious installation approach.
Planning an Industrial Rooftop Solar Project?
VEMCO Solar can help assess your facility’s rooftop feasibility, solar capacity, energy generation potential and project economics and develop a solar EPC solution suited to your requirements.
Contact VEMPL / VEMCO Solar to discuss your industrial or commercial rooftop solar requirement.
