Executive summary
Maintaining solar panel cleanliness is critical for maximizing energy generation, particularly in regions where dust accumulation steadily reduces module performance. At the Ahmadnagar-Kelwad BK solar plant in Maharashtra, traditional cleaning practices faced familiar challenges: water consumption, labor dependency, inconsistent cleaning schedules, and limited visibility into cleaning effectiveness.
To address these challenges, the plant adopted Taypro's NYUMA semi-automatic robotic cleaning system. Operating under a CAPEX ownership model, the deployment introduced a structured, waterless cleaning program designed to improve cleaning consistency while reducing operational dependence on manual washing.
Today, the site utilizes two NYUMA semi-automatic cleaning robots supported by inspection-led operations and documented cleaning schedules across the entire 5 MW facility.
Project Overview
Parameter | Details |
|---|---|
Project Name | Ahmadnagar-Kelwad BK Solar Plant |
Location | Maharashtra, India |
Plant Capacity | 5 MW |
Cleaning Technology | NYUMA Semi-Automatic Robotic Cleaning System |
Total Robots | 2 |
Robots per MW | ~0.40 |
Cleaning Method | Waterless Robotic Cleaning |
Ownership Model | CAPEX |
Monitoring Approach | Inspection-Led Operations & Scheduled Block Plans |
Reported Water Savings | ~700,000 Litres Per Year |
Reported Generation Uplift | ~187.5 MWh Per Year |
Reported Carbon Reduction | ~93 tCO₂e Per Year |
The Operational Challenge
Like many ground-mounted solar installations in Maharashtra, the Ahmadnagar-Kelwad BK plant experiences regular dust deposition caused by agricultural activity, vehicle movement on nearby roads, and seasonal weather conditions. Even moderate soiling can gradually reduce solar module performance if cleaning is delayed or performed inconsistently.
Prior to robotic cleaning, maintaining regular cleaning cycles required significant manpower coordination and water resources. As cleaning intervals extended, operators had limited documentation to verify which blocks had been cleaned, when cleaning occurred, and how those activities correlated with plant performance.
The plant required a more structured approach that could improve accountability, reduce water consumption, and provide repeatable cleaning coverage across the site.
Why NYUMA Was Selected
For a 5 MW facility, flexibility and operational simplicity were key considerations. Rather than deploying a large automated fleet, the plant adopted two NYUMA semi-automatic robotic cleaning units.
The NYUMA platform provides waterless cleaning while allowing technicians to efficiently cover multiple block configurations using portable robotic systems. This approach is particularly effective for small and mid-sized utility-scale plants where operators seek the benefits of robotic cleaning without the infrastructure requirements associated with larger autonomous fleets.
With approximately 0.40 robots per MW, the deployment was designed around actual site requirements rather than generic fleet density benchmarks.
Inspection-Led Cleaning Operations
A defining feature of the Ahmadnagar-Kelwad BK deployment is its inspection-led operational model.
Instead of relying solely on automated scheduling, technicians follow structured weekly block plans that identify cleaning priorities across the plant. Each completed cleaning activity is supported by documented inspection sign-offs, creating a clear operational record that can be reviewed by plant managers and stakeholders.
This process provides accountability while ensuring that cleaning resources are directed toward areas with the greatest potential performance impact.
Responsibilities include:
Weekly cleaning schedule execution
Inspection-based cleaning verification
Brush maintenance and care
Weather-based cleaning holds
Rescheduling of deferred cleaning activities
Performance review and operational reporting
Weather-Aware Cleaning Strategy
Robotic cleaning at Ahmadnagar-Kelwad BK is not based on daily washing schedules. Cleaning activities are planned according to weather conditions, site priorities, and observed soiling behavior.
During periods of elevated dust accumulation, cleaning frequency increases on priority blocks and high-soiling sections of the plant. Following effective rainfall, cleaning activities may be temporarily reduced as natural rinsing lowers immediate cleaning requirements.
Wind conditions are continuously considered when planning operations, ensuring safe and effective robotic cleaning.
This approach optimizes resource utilization while maintaining consistent module cleanliness throughout the year.
Water Conservation Benefits
Water availability is becoming an increasingly important operational consideration for solar asset owners across India.
By replacing routine wet-cleaning activities with waterless robotic cleaning, the Ahmadnagar-Kelwad BK project reports annual water savings of approximately 700,000 litres.
Beyond direct water conservation, the reduction in tanker dependency, transportation logistics, and manual cleaning preparation contributes additional operational efficiencies.
For plant owners focused on sustainability targets and long-term operating costs, these savings create measurable value beyond simple cleaning economics.
Generation Improvement and Performance Impact
The primary objective of any solar cleaning program is to maintain energy production by minimizing losses caused by soiling.
According to site-reported figures, the robotic cleaning program contributes approximately 187.5 MWh of additional annual energy generation.
Although performance improvements vary by site conditions, cleaning frequency, and weather patterns, maintaining cleaner modules throughout the year helps reduce energy losses and supports more predictable plant performance.
Plant owners should validate all generation-related assumptions using site-specific SCADA analysis and performance data before incorporating results into financial models.
Environmental Impact
The combination of water conservation and improved renewable energy generation contributes to the plant's sustainability objectives.
Based on reported operational outcomes, the project is associated with approximately 93 metric tons of CO₂ equivalent reduction annually.
These environmental benefits are increasingly relevant for ESG reporting, investor communications, and sustainability programs across the renewable energy sector.
Commissioning and Site Handover
Deployment activities focused on establishing efficient cleaning routes, identifying priority cleaning zones, and training site personnel on robotic cleaning best practices.
Commissioning included:
Site assessment and cleaning route planning
High-soiling block prioritization
Operator training and safety procedures
Inspection workflow setup
Cleaning protocol implementation
Preventive maintenance guidance
Following commissioning, robotic cleaning became part of the site's regular operations and maintenance strategy.
Lessons for Solar Asset Owners
The Ahmadnagar-Kelwad BK project demonstrates that robotic cleaning can deliver meaningful operational benefits even at smaller utility-scale capacities.
Key takeaways include:
Waterless cleaning significantly reduces dependence on water-intensive maintenance practices.
Inspection-led operations improve accountability and cleaning verification.
Semi-automatic robotic systems provide flexibility for diverse site layouts.
Regular cleaning helps support energy production and reduce soiling losses.
Documented cleaning activities strengthen operational reporting and stakeholder confidence.
Project Results Summary
Metric | Reported Result |
|---|---|
Plant Capacity | 5 MW |
Robotic Fleet | 2 NYUMA Units |
Water Savings | ~700,000 Litres Per Year |
Generation Uplift | ~187.5 MWh Per Year |
Carbon Reduction | ~93 tCO₂e Per Year |
Ownership Model | CAPEX |
Conclusion
The Ahmadnagar-Kelwad BK solar project demonstrates how a compact robotic cleaning deployment can deliver measurable operational and sustainability benefits at a 5 MW utility-scale facility.
Using two NYUMA semi-automatic robots and an inspection-led cleaning strategy, the site established a structured cleaning program that reduces water consumption, improves cleaning accountability, and supports long-term energy generation performance.
For solar plant owners evaluating robotic cleaning solutions, Ahmadnagar-Kelwad BK provides a practical example of how waterless cleaning technology can be successfully integrated into day-to-day solar operations while supporting both performance and sustainability objectives.
All water savings, generation uplift, and carbon reduction figures are site-reported and should be independently validated using plant-specific SCADA data, operating assumptions, and performance models.
