For many factories and workshops in Rajasthan, electricity is one of the largest controllable costs after raw material and labour. The good news is that energy savings usually come from a combination of simple steps: measuring where power is used, fixing waste, upgrading key equipment and generating your own power with solar. This guide explains a practical sequence.
1. Start with an energy audit
You cannot reduce what you do not measure. Collect twelve months of electricity bills and note units consumed, maximum demand, power factor and penalties. Then list major loads — motors, compressors, pumps, furnaces, HVAC and lighting — with their ratings and running hours. A professional energy audit can measure actual consumption and identify losses.
2. Fix the quick wins
- Compressed air leaks: leaks waste a large share of compressor energy in many plants; a leak survey and repair programme is low cost.
- Power factor: maintain capacitor banks so that you avoid low power factor penalties where they apply.
- Idle running: switch off machines, lights and fans when not in use; use timers and interlocks.
- Lighting: replace old fittings with LED high-bay and tube lights and use daylight where possible.
3. Upgrade high-consumption equipment
Motors drive most industrial loads. When old motors fail or need rewinding, consider replacing them with higher-efficiency motors. Variable frequency drives (VFDs) on pumps, fans and blowers that run at part load can reduce consumption significantly. For process heating and cooling, insulation and regular maintenance pay back quickly.
4. Add rooftop or ground-mounted solar
Most factories run during daylight hours, which makes them a good match for solar power. Large industrial roofs can host sizeable systems, and solar generation directly offsets units bought from the grid. The design depends on your roof structure, sanctioned load, DISCOM rules and whether you choose net metering or gross metering. Read our sister company’s industrial rooftop solar planning guide and see ATTPL Solar industrial solutions.
5. Finance the upgrade sensibly
Energy projects are investments with measurable savings. Compare the payback period and lifetime savings with the cost of finance. Options include term loans, equipment finance and, for MSMEs, schemes that support energy efficiency. ATTPL Finance explains solar loan options in detail.
6. Monitor and keep improving
- Install sub-meters on major sections to track consumption.
- Review monthly bills against production to calculate units per unit of output.
- Set a simple target and review it every quarter with the plant team.
If you are planning a new plant, energy efficiency is easiest to build in at the design stage; our guide to setting up a manufacturing unit in Rajasthan covers the wider planning steps.
Frequently asked questions
Where should a factory start to save electricity?
Start with an energy audit and quick wins such as fixing compressed air leaks, improving power factor and switching to LED lighting, before investing in larger upgrades.
Is rooftop solar suitable for every factory?
It suits most factories that operate in daytime and have strong, shadow-free roofs. A site survey checks the roof structure, shading and the capacity allowed by the DISCOM.
Can energy-saving projects be financed?
Yes. Term loans, equipment finance and solar loans are common. Compare the monthly savings with the EMI to judge affordability.
Want a single partner for energy audit, solar and finance? Contact ATTPL (ऐट्प्ल) HOLDCO – GROUP.
