Varroc India Limited – Sambhajinagar Plant
Overview
Varroc India Limited is one of India’s leading global automotive component manufacturers, specializing in electrical, electronic, polymer, and metallic systems for two-wheelers and passenger vehicles. The Sambhajinagar (Aurangabad) facility is a key production hub, equipped with advanced CNC and VMC machining centers for valve and precision metal component manufacturing.
These high-precision machining operations generate considerable heat and contamination—such as oil mist, metallic dust, and fine smoke—which affect both equipment performance and worker comfort. Maintaining adequate temperature, air quality, and exhaust balance was a major operational challenge at this plant.
Project Requirement
- Control the ambient temperature within comfortable limits below 32°C, despite heavy heat load from multiple machining lines.
- Ensure effective exhaust of smoke, oily fumes, and fine dust particles from the machining zone.
- Maintain positive air pressure and enhance indoor air quality to meet industrial health and safety norms.
- Deliver a low-maintenance, energy-efficient alternative to traditional air conditioning for this large production area.
WCSIPL Solution
WCSIPL engineered and executed a turnkey single-stage evaporative cooling system delivering 4,00,000 CFM of supply air and an equal 4,00,000 CFM of exhaust air for effective cross-ventilation.
The system was designed for maximum thermal comfort, odor dilution, and particulate removal while consuming a fraction of the energy of conventional mechanical cooling systems.
Key aspects of the design included
- Industrial-grade single-stage evaporative cooling units with high-efficiency cellulose media pads and centrifugal blowers.
- Zoned air distribution ducting network to deliver uniform air velocity across all machining lines.
- Dedicated exhaust fans with mist eliminators to remove oil-laden and dusty air, maintaining negative pressure in local machining bays.
- Automated controls for fan speed and water circulation to maintain consistent performance and optimize power consumption.
- Robust galvanized steel ducting, powder-coated louvers, and weather-resistant external structures for reliable year-round operation.
System Configuration
- Type of System: Single-Stage Evaporative Cooling with Dedicated Exhaust
- Supply Air Capacity: 4,00,000 CFM
- Exhaust Air Capacity: 4,00,000 CFM
- Air Handling Units: Modular evaporative cooler units with energy-efficient centrifugal fans
- Exhaust Fans: Heavy-duty axial fans with protective wire mesh guards
- Control System: Centralized operation panel with zone-wise monitoring
- Ducting Material: GI Sheet, gauge selected as per static pressure design
- Water System: Gravity feed with FRP sump, automatic float-controlled makeup water
Results Achieved
After commissioning, the system achieved exceptional performance across all zones:
- Temperature Reduction: Maintained process area temperature between 29°C – 32°C even during peak summer.
- Improved Air Quality: Effectively reduced oil mist, machining smoke, and dust, improving visibility and working conditions.
- Odor and Grease Control: Significant reduction in oily and metallic smell from machining zones.
- Energy Efficiency: Recorded over 70% power savings compared to traditional air-conditioning systems.
- Reduced Downtime: Better cooling and clean air led to improved CNC/VMC operational stability and worker productivity.
Key Highlights
- Industry: Automotive Component (Valve Manufacturing, CNC/VMC Machining)
- Location: Sambhajinagar (Aurangabad), Maharashtra
- System Type: Single-Stage Evaporative Cooling + Exhaust Ventilation
- Supply & Exhaust Capacity: 4,00,000 CFM each
- Energy Savings: Approx. 70% over conventional HVAC
- Scope of Work: Turnkey Design, Supply, Installation & Commissioning
- Executed By: Weather Controlling Solutions India Pvt. Ltd. (WCSIPL)
Conclusion
The Varroc India Limited – Sambhajinagar Plant project demonstrates WCSIPL’s expertise in large-volume industrial cooling and ventilation for high-heat, high-contamination environments.
By combining optimized evaporative cooling, engineered exhaust balance, and precision air distribution, WCSIPL delivered a sustainable, cost-effective, and high-performance solution perfectly suited for the demanding conditions of automotive machining operations.