Volkswagen Skoda
Overview
Skoda Auto Volkswagen India Pvt Ltd is part of the Volkswagen Group, one of the world’s largest automotive manufacturers. The Chakan facility is a state-of-the-art automotive manufacturing plant dedicated to producing Volkswagen vehicles (VW 2.0 project), including engine assembly, body shop operations, and final assembly lines.
The production environment requires stringent temperature control and dust-free air to ensure high-quality vehicle assembly and optimal worker conditions.
Project Requirement
In 2022, the client approached Weather Controlling Solutions India Pvt. Ltd. (WCSIPL) for a high-capacity industrial HVAC solution to maintain:
- Process area temperature: 27°C ± 2°C across engine shop, body shop, and assembly line.
- Air quality: Dust-free and comfortable working conditions for operators and equipment.
- High airflow requirement: Approximately 11,00,000 CFM supply with balanced exhaust.
- Energy efficiency: Cost-effective alternative to conventional air conditioning for large-volume production areas.
The solution also needed to integrate roof-mounted exhaust fans to effectively remove heat, fumes, and maintain positive airflow balance.
WCSIPL Solution
WCSIPL implemented a two-stage evaporative cooling system with roof-mounted exhaust fans for a large-volume airflow application.
System Features:
- Air Supply: 11,00,000 CFM of cooled and filtered air distributed across engine, body, and assembly areas.
- Exhaust System: Roof-mounted exhaust fans handling equivalent CFM for uniform air extraction.
- Temperature Control: High-precision control maintaining 27°C ± 2°C with real-time monitoring.
- Zonal Distribution: Separate supply zones for engine, body, and assembly for targeted cooling and comfort.
- Energy Efficiency: Reduced power consumption by up to 65% compared to conventional AC systems of similar capacity.
The system was designed to handle high heat loads, dust particles, and process-related fumes while maintaining continuous production without downtime.
System Configuration
WCSIPL designed and executed a complete Two-Stage Evaporative Cooling System on a turnkey basis,
including design, supply, installation, and commissioning.
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Parameter
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Specification
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Type of System
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Two-Stage Evaporative Cooling
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Supply Air
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11,00,000 CFM
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Exhaust Air
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Roof-mounted fans, 11,00,000 CFM
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Areas Covered
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Engine Shop, Body Shop, Assembly Lines
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Temperature Maintained
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27°C ± 2°C
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Control
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Centralized monitoring for temperature and airflow
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Energy Savings
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Approx. 65% over conventional AC
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