CASE STUDIES

Bakery

Diamond Bakery Reduces Backup Power Costs by 38% with a 100% LPG Powered GenSet

Executive Summary

Diamond Bakery, a leading food processing unit in Pune, required a reliable and hygienic power backup solution to support uninterrupted production. The existing diesel-powered GenSet resulted in high operating costs, emissions, increased maintenance, and was not aligned with the company’s sustainability objectives.

Pune Gas implemented a 100% LPG Powered Generac GenSet supported by a 47.5 kg LOT LPG cylinder system. The solution delivered significant fuel cost savings, cleaner operations, lower maintenance, and reliable backup power while enhancing workplace safety and environmental performance.

Key Stats

Weekly Fuel Savings
0 KG
Daily Fuel Savings
0 KG
Annual Cost Savings
0 Lakhs/Year

Before (Diesel GenSet)

Monthly
  • High and volatile diesel operating costs
  • Fuel consumption: ~4.3 litres/hour
  • Cost per hour: ₹389
  • Cost per unit: ₹28.6/kWh
  • Soot, fumes, noise and diesel spillage
  • High maintenance requirements

After (100% LPG Powered GenSet)

Monthly
  • Fuel consumption: ~2.8 kg/hour
  • Cost per hour: ₹241
  • Cost per unit: ₹17.7/kWh
  • ~38% reduction in fuel costs
  • Monthly savings: ~₹35,500
  • Annual savings: ~₹4.25 Lakhs
  • ~28% reduction in CO₂ emissions

Client Overview

Diamond Bakery is a high-volume food processing facility based in Pune, where uninterrupted power is essential to maintain production continuity, product quality, and food safety standards. The company required a dependable and cost-effective standby power solution that aligned with modern sustainability and operational goals.

The Challenge

Operating on a diesel-powered GenSet created multiple operational constraints:

  • High and fluctuating diesel costs
  • Soot and emissions unsuitable for food processing environments
  • Noise and odour affecting workplace conditions
  • High maintenance requirements
  • Limited alignment with ESG and sustainability objectives

The existing backup power infrastructure no longer supported the company’s efficiency, hygiene, and environmental expectations.

The Solution

Pune Gas implemented a 100% LPG Powered Generac GenSet integrated with a 47.5 kg LOT LPG cylinder system, engineered for reliable standby power in food processing applications.

The solution delivered:

  • 17 kVA Generac LPG GenSet operating on 100% LPG
  • Fuel supply through 47.5 kg LOT LPG cylinders
  • Seamless and reliable standby power operation
  • Compliance with food industry safety standards
  • Cleaner combustion with lower operating costs

Measured Savings and Operational Gains

  • Fuel Cost Reduction
    Reduced backup power costs by approximately 38%, delivering monthly savings of ~₹35,500 and annual savings of ~₹4.25 Lakhs.
  • Operational Efficiency
    Fuel costs reduced from ₹389/hour to ₹241/hour, with the cost per unit decreasing from ₹28.6/kWh to ₹17.7/kWh.
  • Cleaner Operations
    Complete elimination of soot, diesel fumes, and fuel spillage, creating a cleaner production environment.
  • Environmental Improvement
    Approximately 28% reduction in CO₂ emissions, supporting the company’s sustainability initiatives.
  • Operational Reliability
    Consistent backup power with smoother operation, faster start-up, and reduced maintenance requirements.

Execution

The Pune Gas team successfully installed and commissioned the 17 kVA LPG Powered Generac GenSet with seamless integration into Diamond Bakery’s existing operations. The system was configured to ensure uninterrupted standby power while maintaining the highest standards of operational safety and reliability.

Conclusion

By transitioning from diesel to a 100% LPG Powered GenSet, Diamond Bakery significantly reduced backup power costs while improving operational efficiency, workplace hygiene, and environmental performance. The solution demonstrates how cleaner energy systems can simultaneously enhance reliability, sustainability, and long-term operating economics in food processing facilities.