Project Mirfak, Sungazing Solar Plant, India | 2.5 MW Waterless Robotic Solar Panel Cleaning Case Study

The Sungazing Solar Plant is a 2.5 MW ground-mounted solar power project in India that adopted Taypro's NYUMA semi-automatic robotic cleaning solution to improve module cleanliness, reduce water dependency, and create a structured maintenance program for long-term asset performance. Commissioned with five NYUMA waterless solar cleaning robots in 2025, the project demonstrates how small and mid-sized utility-scale solar plants can achieve reliable cleaning frequency without relying on labor-intensive manual washing practices.

For solar asset owners, EPC contractors, O&M companies, and investors evaluating robotic cleaning technology, Sungazing provides a practical example of how portable robotic cleaning systems can deliver measurable operational benefits without requiring a large autonomous fleet. The project combines inspection-led cleaning schedules, waterless operation, and disciplined maintenance planning to support generation performance while reducing operating complexity.

Project Overview

Executive Summary

Dust accumulation remains one of the most persistent challenges for solar power plants across India. Even at smaller utility-scale installations, module soiling can gradually reduce energy production, increase maintenance effort, and create uncertainty around performance ratio recovery.

At the Sungazing Solar Plant, Taypro deployed five NYUMA semi-automatic waterless solar cleaning robots to establish a structured cleaning program that eliminates routine water consumption while improving cleaning frequency and operational accountability.

Site operations report approximately 350,000 litres of water savings annually, along with an estimated 93.8 MWh of additional clean energy generation and approximately 47 metric tons of CO₂ equivalent impact each year. These figures are site-reported and should always be validated against plant-specific SCADA data and performance methodologies.

Most importantly, the project demonstrates that robotic cleaning is not about daily washing. Instead, it is about scheduled cleaning cycles, weather-aware decision-making, documented inspections, and consistent maintenance discipline that supports long-term solar asset performance.

The Challenge Before Robotic Cleaning

Prior to implementing robotic cleaning, the plant faced challenges that are common across many utility-scale solar projects:

• Dust accumulation reducing module performance between cleaning cycles.
• Dependence on manual labor availability.
• Water sourcing and transportation requirements.
• Inconsistent cleaning frequency during high-soiling seasons.
• Difficulty documenting cleaning completion for operational reviews.
• Challenges maintaining optimal performance ratio during dry periods.

Although the plant capacity is relatively modest at 2.5 MW, maintaining consistent cleaning standards remained critical because even small percentage losses in module performance can translate into measurable annual energy losses.

Why Sungazing Chose NYUMA Semi-Automatic Robots

Rather than deploying a fully autonomous robotic fleet, Sungazing selected a semi-automatic cleaning strategy based on five NYUMA robots. This approach offered flexibility, portability, and lower deployment complexity while still enabling regular waterless cleaning across the entire solar field.

Semi-automatic robots are particularly effective for plants where operators prefer direct control over cleaning schedules and where row layouts, operational preferences, or maintenance strategies favor portable equipment.

With approximately 2.0 robots per MW, the plant maintains strong operational coverage while retaining the flexibility to prioritize specific blocks whenever seasonal dust conditions require increased attention.

Waterless Cleaning for Sustainable Solar Operations

Water scarcity is becoming an increasingly important operational consideration for solar power plants throughout India. Traditional wet cleaning methods often require significant quantities of water, tanker logistics, labor coordination, and additional site management.

The NYUMA robotic cleaning solution eliminates routine water usage by utilizing a dry, waterless cleaning process specifically designed for solar module maintenance.

At Sungazing, site operations estimate annual water savings of approximately 350,000 litres when compared against conventional cleaning approaches. Beyond direct water conservation, eliminating regular washing activities also reduces:

• Water transportation costs.
• Tanker scheduling requirements.
• Water storage infrastructure dependency.
• Runoff management concerns.
• Operational disruptions associated with wet cleaning.

For solar asset owners focused on ESG reporting and sustainability objectives, water conservation remains one of the most measurable benefits of robotic cleaning adoption.

Cleaning Operations and Scheduling Strategy

A common misconception about robotic cleaning is that every module is cleaned every night. In reality, effective robotic cleaning programs rely on structured schedules based on environmental conditions, soiling behavior, and operational priorities.

At Sungazing, cleaning activities are organized through inspection-led planning and documented weekly schedules. Supervisors review operating conditions and prioritize cleaning blocks according to site requirements.

Key considerations include:

• Dust accumulation trends.
• Weather forecasts.
• Wind conditions.
• Rainfall events.
• Maintenance activities.
• Performance observations from inverter and SCADA data.

When rainfall provides effective natural cleaning, cleaning schedules can be adjusted accordingly. During peak dust periods, cleaning frequency can increase to maintain performance consistency.

Commissioning and Site Deployment

The robotic cleaning system was commissioned in 2025 following a structured deployment plan designed to ensure reliable long-term operation.

The commissioning process included:

• Site layout assessment.
• Cleaning route validation.
• Block prioritization.
• Operator training.
• Maintenance planning.
• Safety procedure implementation.
• Operational documentation setup.

Special attention was given to training site personnel on robot operation, cleaning schedules, maintenance procedures, weather-related holds, and cleaning documentation requirements.

Performance Monitoring and SCADA Correlation

One of the most important lessons from the Sungazing project is the importance of connecting cleaning activity with plant performance data.

Rather than relying solely on visual inspections, operators are encouraged to compare cleaning records with SCADA trends, inverter performance data, and plant production metrics.

When performance recovery does not align with cleaning activity, operators can investigate potential causes such as:

• Uneven soiling.
• Module degradation.
• Electrical issues.
• Equipment faults.
• Partial cleaning coverage.
• Brush wear.

This data-driven approach improves operational transparency and strengthens long-term asset management.

Environmental Impact and ESG Benefits

Environmental performance is increasingly important for developers, investors, lenders, and corporate energy buyers.

The Sungazing project demonstrates how robotic solar cleaning can contribute to sustainability objectives through measurable operational outcomes.

Reported annual benefits include:

• Approximately 350,000 litres of water conserved.
• Approximately 93.8 MWh of additional clean energy generation.
• Approximately 47 metric tons of CO₂ equivalent impact.

While these figures should be validated through plant-specific methodologies, they illustrate how cleaning optimization can contribute directly to broader ESG and sustainability goals.

Seasonal Operating Strategy

Solar cleaning requirements vary significantly throughout the year.

January to February

• Review brush condition.
• Assess cleaning schedules.
• Update inspection procedures.
• Prepare for summer dust conditions.

March to June

• Peak dust season.
• Increase cleaning frequency where required.
• Monitor inverter trends closely.
• Prioritize high-soiling blocks.

Monsoon Period

• Reduce cleaning activity after effective rainfall.
• Focus on inspections and operational verification.
• Monitor for localized mud spotting.

Post-Monsoon

• Inspect access routes.
• Review vegetation growth.
• Update cleaning plans.
• Prepare for the next dry season.

Lessons for Solar Plant Owners

The Sungazing project provides several important lessons for solar asset owners considering robotic cleaning technology:

• Waterless cleaning can deliver measurable sustainability benefits.
• Smaller utility-scale plants can successfully implement robotic cleaning.
• Semi-automatic systems remain highly effective when supported by structured operational discipline.
• Cleaning accountability matters as much as cleaning frequency.
• Inspection records and performance analysis should be integrated into maintenance programs.
• Robot density alone should not determine procurement decisions.
• Site-specific layouts and soiling patterns must guide fleet sizing.

Procurement Considerations for Future Projects

Organizations evaluating robotic cleaning should consider:

• Plant layout and row geometry.
• Dust exposure levels.
• Water availability.
• Labor requirements.
• SCADA integration requirements.
• Maintenance planning.
• Training needs.
• Long-term operational objectives.

A successful robotic cleaning deployment depends on aligning technology selection with actual site conditions rather than simply replicating robot counts from other projects.

Why Sungazing Is a Valuable Benchmark

Many robotic cleaning case studies focus on very large utility-scale assets. Sungazing provides a different perspective by demonstrating how a 2.5 MW solar plant can successfully implement a portable robotic cleaning strategy while maintaining strong operational discipline.

For developers and asset owners operating small and mid-sized solar facilities, the project offers a practical example of how waterless robotic cleaning can improve sustainability, support performance optimization, and establish a repeatable maintenance framework without requiring a large autonomous fleet.

Conclusion

The Sungazing Solar Plant showcases the practical benefits of semi-automatic robotic solar panel cleaning for utility-scale solar operations. Through the deployment of five NYUMA waterless cleaning robots, the project established a structured cleaning program that supports generation performance while reducing water dependency and improving operational accountability.

With reported annual savings of approximately 350,000 litres of water, an estimated 93.8 MWh of additional clean energy generation, and approximately 47 metric tons of CO₂ equivalent impact, Sungazing demonstrates how robotic cleaning can contribute to both operational efficiency and sustainability objectives.

For solar developers, EPC companies, investors, and O&M teams evaluating robotic cleaning technologies, Sungazing serves as a strong example of how disciplined planning, waterless cleaning, and consistent operational execution can create long-term value from a relatively compact solar asset.