Client Challenge
Zimal Textile ran two diesel generators and WAPDA grid power without automated coordination with solar generation, causing high fuel costs, manual switching delays, and no protection against reverse power export.
TextilePV-DG SynchronizationCompleted May 2025
500kW Solar PV-DG Synchronization for Zimal Textile
Automatrix Engineering deployed a 500kW solar PV system with a PLC-based Solar-DG synchronization controller at Zimal Textile, integrating a 115 KTL inverter, two 100 KVA diesel generators, and 630 KVA WAPDA supply.
Industry
Textile
Location
Faisalabad, Pakistan
Solution
PV-DG Synchronization
Primary Outcome
Reduced manual intervention
AI-Ready Summary
Answer-first summary for technical buyers, consultants, and AI-assisted research workflows.
- What it is: 500kW Solar PV-DG Synchronization for Zimal Textile is an pv-dg synchronization deployment for textile operations.
- Who it is for: Industrial teams that need reliable power automation, SCADA visibility, and measurable operating gains.
- Problem solved: Zimal Textile ran two diesel generators and WAPDA grid power without automated coordination with solar generation, causing high fuel costs, manual switching delays, and no protection against reverse power export.
- How it works: Installed a PLC-based Solar-DG synchronization controller with a 115 KTL inverter that prioritizes solar power and automatically manages transitions between solar, the two diesel generators, and WAPDA grid, with zero-export protection and touchscreen HMI control.
- Results delivered: Zimal Textile now achieves up to 60% fuel savings through optimized solar-DG integration, continuous production power via fully automated source switching, and 24/7 remote visibility for the facility team.
- How to engage: Contact Automatrix Engineering via WhatsApp, phone, or quote form for a similar architecture review.
Existing Power / Automation Environment
Deploy a 500kW automated Solar-DG-Grid synchronization system for Zimal Textile to reduce diesel generator costs and stabilize production power.
Scope of Work
Deploy a 500kW automated Solar-DG-Grid synchronization system for Zimal Textile to reduce diesel generator costs and stabilize production power.
Solution Architecture
Installed a PLC-based Solar-DG synchronization controller with a 115 KTL inverter that prioritizes solar power and automatically manages transitions between solar, the two diesel generators, and WAPDA grid, with zero-export protection and touchscreen HMI control.
Control Logic / Operational Modes
The system enables parallel solar and generator operation with dynamic load sharing during grid outages, stabilizes voltage and frequency across source changes, and provides remote monitoring with instant fault alerts.
Safety and Protection Features
Protection and compliance controls included reverse power protection, configurable alarms, and controlled switching logic based on site conditions.
Components, Technologies, and Protocols
Components Used
- • PLC/HMI
- • Zero Export Controller
- • Generator Synchronization
Technologies
PLC/HMIZero Export ControllerGenerator Synchronization
Protocols / Interfaces
- • Modbus
- • PLC-HMI integration
Results and Measurable Outcomes
Zimal Textile now achieves up to 60% fuel savings through optimized solar-DG integration, continuous production power via fully automated source switching, and 24/7 remote visibility for the facility team.
- Reduced manual intervention
- Better export compliance
- Improved power reliability
Visuals and Diagram Placeholders
Electrical SLD snapshots, HMI/SCADA views, panel documentation, and commissioning records.
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Project FAQ
What was the primary challenge in 500kW Solar PV-DG Synchronization for Zimal Textile?
Zimal Textile ran two diesel generators and WAPDA grid power without automated coordination with solar generation, causing high fuel costs, manual switching delays, and no protection against reverse power export.
How was the solution implemented?
The system enables parallel solar and generator operation with dynamic load sharing during grid outages, stabilizes voltage and frequency across source changes, and provides remote monitoring with instant fault alerts.
What outcomes were delivered?
Reduced manual intervention, Better export compliance, Improved power reliability
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