Shan Foods, one of Pakistan’s most recognized food brands, has taken a strategic step toward sustainability by installing a 450KW grid-tied solar power plant at its Karachi facility. With a strong global presence, Shan continues to align its operations with modern, responsible energy practices. The project was successfully executed by DSG Energy, delivering a reliable and efficient solar solution tailored to industrial needs. This initiative supports reduced energy costs and reinforces a commitment to sustainable growth. This initiative highlights Shan Foods’ forward-thinking approach and sets a strong example for renewable energy adoption in Pakistan’s industrial sector.

Technological Excellence

The project leverages the high-performance capabilities of Canadian Solar 585W N-Type Bi-Facial Panel, renowned for their efficiency, durability, and reliable energy output in industrial environments. These advanced modules are designed to deliver superior energy conversion while maintaining consistent performance under varying weather conditions. Their robust construction ensures long-term reliability, making them ideal for large-scale rooftop installations. By incorporating these premium panels, Shan Foods benefits from optimized energy generation, reduced electricity costs, and a more sustainable and efficient power solution.

Advanced Inverter Technology

At the core of this solar power system are Huawei 115 KTL string inverters, recognized for their advanced performance and reliability. Their selection by DSG Energy reflects strong expertise in delivering high-performance solar solutions for demanding industrial environments like Shan Foods.

Equipped with multi-MPPT (Maximum Power Point Tracking) technology, these inverters optimize energy output across different sections of the solar array, ensuring maximum efficiency even under varying conditions such as shading or panel orientation differences. In addition, the system benefits from intelligent monitoring and advanced grid management capabilities, enabling real-time performance tracking, quick fault detection, and consistent optimization of the plant’s energy output.

Efficient Foundation

For this rooftop installation at Shan Foods, DSG Energy engineered and deployed an MS (Mild Steel) Epoxy Painted 15ft Elevated Structure— a mounting solution specifically designed to meet the unique structural, environmental, and aesthetic requirements of the facility’s roof. This elevated mounting framework is precision-fabricated to provide the ideal tilt angle for the solar panels, maximizing sunlight capture given Karachi’s geographic latitude and ensuring optimal annual energy generation, and is designed to withstand wind speeds of up to 35 m/s.

The choice of mild steel with a high-quality epoxy paint coating provides multiple layers of protection for the structure. The epoxy coating forms a robust barrier against the corrosive effects of Karachi’s coastal environment, where salt-laden air and high humidity levels can rapidly degrade unprotected steel. By selecting epoxy-painted MS structures, DSG Energy has ensured that the mounting framework will remain structurally sound and corrosion-resistant throughout the system’s operational lifetime.

The elevated design of the structure also serves an important functional purpose: it creates a gap between the panels and the roof surface, allowing for natural airflow that helps cool the panels and maintains their efficiency, while also facilitating easy access for maintenance personnel. Dedicated walkways and staircases are incorporated into the design, ensuring safe access in compliance with OSHA standards for inspection, cleaning, and servicing.

Enhanced Stability and Longevity

To ensure long-term structural reliability, DSG Energy designed a robust rooftop mounting system that safely distributes the solar array load across the existing structure without compromising its integrity at Shan Foods.

The system incorporates precise load calculations, along with anti-vibration and wind-resistant features to withstand Karachi’s challenging weather conditions. Additionally, the MS epoxy painted elevated structure allows for thermal expansion, reducing mechanical stress over time.

This engineering approach ensures a stable, durable, and low-maintenance solar installation capable of delivering reliable performance for decades.

Power Management

One of the key highlights of this project is the seamless integration of the 450KW solar system with Shan Foods existing power infrastructure, including the K-Electric grid and a genset backup system. DSG Energy implemented a smart controller-based solution to efficiently manage all power sources, enabling tri-source integration (Solar + Gas Genset + K-Electric supply).

One of the key highlights of this project is the seamless integration of the 450KW solar system with Shan Foods’ existing power infrastructure, including the K-Electric grid and a genset. DSG Energy implemented a smart controller-based solution to efficiently manage all power sources.

During daylight hours, solar energy acts as the primary source, significantly reducing reliance on grid/genset electricity. When solar output is low, the system automatically draws power from the grid/genset, ensuring uninterrupted operations.

Project Challenges

DSG Energy implemented strict safety protocols throughout the project. For rooftop work, mandatory harnesses, fall-arrest systems, and dedicated safety officers ensured zero incidents. Confined space cable routing through ceiling voids and cable trays was managed with atmospheric monitoring, buddy systems, and pre-optimized routing plans. For power integration, a custom controller synchronizes solar, grid, and genset seamlessly — tested through simulated outage scenarios before commissioning to ensure fully automatic handover.

Final Thoughts

The 450 KW solar installation at Shan Foods marks a landmark achievement in Pakistan’s food manufacturing sector. Combining Canadian Solar 585W panels, Huawei 115 KTL inverters, and a smart tri-source power management system, DSG Energy has delivered a reliable, high-performance solution — setting a benchmark for sustainable industrial practices in Pakistan.

Achieving Sustainability with Solar Energy

By installing a 450kW solar power system into Shan Foods’ infrastructure, DSG Energy has significantly enhanced the facility’s energy generation capacity to 657 MWH. This implementation has also resulted in a CO₂ reduction of approximately 350 metric tons, equivalent to the planting of 17,000 trees, showcasing Shan Foods’ strong commitment to sustainability and environmental responsibility.

LET’S KEEP MOVING TOWARDS A GREENER FUTURE!