Supporting Clean Energy at Scale: How Manufacturing Agility Enabled the World's Largest Solar Park
With end-to-end manufacturing control, Karkhana.io ensured this clean energy project was delivered without compromise.
Overview
When the world sets its sights on clean energy, the scale of ambition is immense. One such project—undisputedly the largest solar park on the planet—demanded not just vision, but also robust execution on the ground. Among the critical enablers of this execution were the humble but essential purlin plates—structural components that support and stabilize solar panels across thousands of acres.
While the engineering challenges of a solar park are well-documented, what often gets overlooked is the manufacturing muscle required to bring these structures to life. From precision fabrication to high-volume procurement and coordinated logistics, the behind-the-scenes work can make or break such a project.
With end-to-end manufacturing control, Karkhana.io ensured this clean energy project was delivered without compromise.
Project at a Glance
When the world sets its sights on clean energy, the scale of ambition is immense. One such project—undisputedly the largest solar park on the planet—demanded not just vision, but also robust execution on the ground. Among the critical enablers of this execution were the humble but essential purlin plates—structural components that support and stabilize solar panels across thousands of acres.
While the engineering challenges of a solar park are well-documented, what often gets overlooked is the manufacturing muscle required to bring these structures to life. From precision fabrication to high-volume procurement and coordinated logistics, the behind-the-scenes work can make or break such a project.
With end-to-end manufacturing control, Karkhana.io ensured this clean energy project was delivered without compromise.
Industry:
Renewable Energy & Utility-Scale Solar
Product:
High-volume fabrication and supply of purlin plates and consumables for the world’s largest solar park
Services Offered
Turnkey manufacturing partnership, supply chain consolidation, quality assurance, strategic procurement, inspection management, logistics coordination
Capabilities Leveraged
Precision fabrication, design optimization, internal QA/pre-check systems, end-to-end logistics management
High Stakes, High Volumes, No Room for Error
The project stakeholders were already clear on the design and specifications. But turning those drawings into real-world components—and doing so at the scale required—posed serious execution challenges.
Supplier coordination
With multiple suppliers across various locations, managing consistency and timelines was becoming increasingly complex.
Quality control
The purlin plates had tight fabrication tolerances, which meant even small deviations could lead to assembly issues on-site.
Procurement of consumables
Post-processed consumables had to be sourced and customized at high volumes, adding another layer of supply chain complexity.
Inspection cycles
Multiple rounds of third-party inspections were leading to delays.
Logistics management
Delivering high-volume fabricated parts and consumables within a narrow timeframe demanded precision scheduling.
The Challenge: Scaling Sustainably Without Compromise
At the heart of Pi Green’s Carbon Cutter is a drum assembly that demands precise fabrication, critical tolerance controls, and robust surface treatments. While the team had an early supplier network in place, they soon found themselves constrained by limited production capacity and inconsistent quality.
Dry Film Thickness (DFT) for painting and coating posed another challenge — with environmental performance directly tied to the quality of surface finish. Moreover, the lack of a strong supplier base made it difficult to react quickly to scale-up demands or resolve process bottlenecks. They needed not just a vendor, but a manufacturing partner who could co-own the problem.
The Solution: End-to-End Manufacturing with Built-In Coordination
Karkhana.io stepped in as the central manufacturing partner, deploying a fully managed solution that combined deep supplier networks with tight operational oversight.
To streamline supplier coordination, a dedicated project management team was assigned to oversee fabrication across multiple vetted suppliers. Using real-time digital tracking, the team was able to monitor manufacturing progress, flag issues early, and ensure that delivery timelines were met without compromising quality.
For maintaining critical fabrication tolerances, the production process was tightly aligned to a Quality Assurance Plan. In parallel, design optimizations were introduced to improve interchangeability and accelerate on-site assembly—crucial when every delay could compound across thousands of solar panel rows.
On the procurement front, Karkhana.io’s team identified the right suppliers for customized consumables and managed the entire post-processing workflow. Full documentation and traceability were built into the system to support compliance and future audits.
To reduce bottlenecks around third-party inspection, internal quality checks were conducted in advance. This allowed third-party inspections to proceed with greater efficiency, supported by comprehensive documentation and coordinated scheduling—resulting in a notable reduction in turnaround times.
Finally, logistics were handled with the same level of orchestration. Fabricated parts and consumables were dispatched from different locations across India, with transportation and production schedules aligned to minimize lead times.
An Integrated Manufacturing Solution
We stepped in as a turnkey manufacturing partner, offering a centralized solution to an otherwise fragmented supply chain. Here’s how we tackled each challenge with precision:
Consolidating the Supply Chain
Rather than juggling vendors, the project was brought under one roof through our vetted supplier network. Our dedicated project management team coordinated activities across fabrication partners, enabling seamless communication and real-time status tracking across all manufacturing nodes.
Enforcing Fabrication Quality
Every purlin plate had to meet tight tolerances to ensure smooth on-ground deployment. We created a quality assurance plan tailored for the project, mapping out process checkpoints and controls. Our engineering team further optimized the design to ensure interchangeability and minimize on-site adjustments.
Strategic Procurement of Consumables
The project involved sourcing and processing high volumes of specialized consumables. We identified capable suppliers, handled custom post-processing requirements, and ensured all documentation and material traceability was airtight—critical for audits and future maintenance.
Streamlining Inspections
To reduce third-party inspection delays, we introduced internal pre-checks using calibrated tools and expert QA teams. We also owned the inspection process end-to-end—scheduling, coordination, and reporting—so that only compliant parts reached the next stage. This drastically cut down inspection iterations.
Logistics Optimization
Managing movement across India for thousands of fabricated parts and consumables required tight logistics planning. We synchronized production and transportation schedules to reduce idle time, shipping errors, and part mismatches. That meant less waiting, fewer reschedules, and faster throughput.
Tangible Results That Scaled
With a combination of integrated execution, robust QA, and smart coordination, the project achieved results that would be hard to replicate in a fragmented setup:
Zero manufacturing rejections across ~2.7 lakh components
2.7 lakh components delivered in just 45 days
50% reduction in quality process turnaround time
80% reduction in customer-side manpower utilization
More than just numbers, the outcome was a smooth, scalable supply chain that allowed Pi Green to focus on product innovation while Karkhana.io took care of execution.
Why Integrated Execution Matters at Scale
Clean energy projects don’t just need good design—they need agile, scalable, and quality-first manufacturing execution. And in an industry where speed, traceability, and precision can all be deal-breakers, finding a partner that can deliver more than just parts is critical.
This project demonstrated what’s possible when manufacturing is not treated as a linear task but as a coordinated ecosystem—from procurement to production to delivery.
In building the world’s largest solar park, every component mattered. And in delivering those components right, manufacturing became a quiet but essential driver of the clean energy transition.
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