Project Details
Project: Haldiram’s Industrial Facility
Location: Nagpur
Roof Type: RCC Roof
Area Covered: 1,00,000 Sq. Ft.
Number of Coatings Applied: 3 Coats
Project Delivery Time: 40 Days
Nagpur is famous for its very hot summers, which makes it difficult for big factory buildings to stay cool and save electricity. Haldiram’s, which is also situated in Nagpur, faces the same problem. At the Haldiram’s production and storage facility – one of India’s most popular snack and sweets brands, known for Bikaneri bhujia, namkeen mixtures, and sweets like gulab jamun – this problem became serious because of its RCC roof. The roof covers a very large area and stays under direct sunlight the whole day. Instead of reflecting the heat, it absorbed it and slowly released it inside the building, making the indoor area much hotter.
The rising indoor temperature began affecting worker comfort, storage conditions, and overall productivity. To cool it down, multiple cooling systems had to run continuously, which led to increased electricity consumption and higher operational costs. Alongside this, the production facility also had installed solar panels on the roof. For better performance, they installed bifacial solar panels, which perform better when surrounding surfaces reflect more sunlight rather than absorbing it. But excessive roof temperature also reduced its efficiency.
To overcome these challenges, Indian Insulation and Engineering Company, a specialist in industrial thermal management and cool roof solutions, delivered a long-term energy-saving solution with its High Albedo Paint Cool Roof Coating Service. The solution was specifically designed for large-scale industrial roofs and solar-integrated facilities.
The Problem: Heat Load & Solar Performance Issues
Before the project, the facility struggled with:
- Excessive heat absorption from the RCC roof during peak summers
- Higher indoor temperatures are affecting the working environment
- Increased HVAC load and electricity consumption
- Reduced efficiency of installed bifacial solar panels
- Inconsistent performance of bifacial (bi-panels) solar modules
Since bifacial solar panels generate power from both sides, the dark concrete roof was limiting reflected light and lowering energy generation.
The Solution: High Albedo Reflective Coating
The Haldiram’s production and storage facility contact Indian Insulation and Engineering company and quotes the requirement of high albedo paint for 1 lac sq feet roof area, and also tells how the bifacial solar panels are not efficient in reducing the excessive power consumption of cooling devices. After the consultation, our team went to the site and inspected it.
The team found that the 1 lac sq feet roof area is the type of RCC roof. A Reinforced Cement Concrete (RCC) roof is a strong, solid structure made of concrete with steel bars inside. This combination helps the roof handle both bending and compression forces effectively. But one of its disadvantages is that it causes high temperatures. On the other hand, the colour of this roof was dark, which absorbs more heat and reflects less sunlight. Thus, the bifacial solar panel system, a two-sided solar system that absorbs the light from both sides, does not get enough light reflection from the roof because of its dark colour and has less reflection.
After assessing the structure, the team of Indian Insulation and Engineering applied 3 coats of COOLROOF® – High Albedo Paint, coating across approximately 1,00,000 sq. ft. of RCC roof area within a 40-day execution period.
After the complete application, the facility observed a noticeable reduction in roof surface temperature, which helped stabilise indoor conditions and reduced dependence on mechanical cooling. The cooler roof environment also improved the performance of the installed solar panels by enhancing light reflectivity around them. This was particularly beneficial for bifacial solar panels, as the reflective surface increased rear-side energy generation. The coating significantly reduced heat absorption by reflecting a major portion of solar radiation back into the atmosphere.
With improved thermal comfort, reduced energy consumption, and enhanced solar output, Haldiram’s Nagpur facility successfully transformed its rooftop into an energy-efficient and productivity-supporting surface – demonstrating how high albedo coating can be a practical and sustainable solution for industrial infrastructure in hot climatic regions.
The Results: Cooler Building & Higher Solar Output
After completion of the project, the facility experienced measurable improvements:
Thermal Benefits
- Significant reduction in roof surface temperature
- Cooler indoor working environment
- Reduced HVAC load
- Improved comfort for workers
- Energy Savings
- Lower electricity consumption for cooling
- Reduced peak load demand
- Solar Performance Improvement
- Increased efficiency of bifacial solar panels
- Higher solar power generation due to reflected radiation
- Better ROI on solar installation
- Operational Benefits
- Large-area coverage improved overall energy balance
- Long-lasting protection for RCC roof
- Reduced heat stress on building structure
Why High Albedo Paint Matters for Solar Panels
Even Government bodies and energy authorities promote and suggest high albedo coatings when you install a solar panel system on your roof because they directly improve solar generation efficiency.
For bifacial solar panels:
- Light reflected from the white roof hits the backside of the panels
- More reflected radiation = more power generation
- Larger coated area = higher efficiency gain
Final Words
The High Albedo Roof Coating done at the Haldiram’s Nagpur factory shows how a special reflective paint can do more than just cool a building but it can also help solar panels work better. After applying the coating on about 1 lakh sq. ft. of roof, the building became cooler inside, and the solar panels started performing more efficiently. This project proves that big factory rooftops are not just empty space, they can be turned into energy-saving and money-saving surfaces, especially when used with bifacial solar panels.
