Auto-Component Factory.3 Air Curtains. 31% Power Saved.
An auto-component manufacturer in Surajpur Industrial Area, Greater Noida (UP) had a constant forklift-traffic problem at the main loading bay — losing chilled air efficiency and inviting dust into the assembly line. Chronovex engineered 3× 2-Meter industrial air curtains with high-CFM motors. 18 months later: 31% power saved, 68% dust drop tracked on quarterly maintenance.
When the loading bay is also the AC leak
Manufacturing plants in the Surajpur-Greater Noida cluster face a recurring tension: loading bays need to be wide-open for inbound material flow, but every forklift trip pumps Delhi-NCR dust and summer heat into climate-controlled assembly halls.
7.5m wide loading bay, forklift every 4 minutes, AC running 24×7
The plant manager, Ashish Kumar, had two pain points: (1) the assembly line operating at 24°C required constant HVAC over-run because the loading bay's 7.5m roller shutter was fully open during shift hours, (2) dust on the conveyor was triggering quality rejections on precision auto-components averaging 3.2% — above the 1.5% threshold.
Forklift cycle vs HVAC cycle vs dust cycle
Our manufacturing vertical lead, Sanjay Rao (B.E. Mechanical + 16 yrs industrial HVAC), did a 48-hour shift study. Findings: every forklift cycle caused a 4.2°C temperature spike at the assembly line, taking the chiller 11 minutes to recover. Dust spikes correlated 0.91 with forklift movement on regression analysis.
3× 2-Meter heavy-duty air curtains, 1500W motors, sequenced auto-on
We deployed 3 industrial-grade 2-Meter air curtains across the 7.5m bay opening, mounted at 3.2m height, angled 12° outward, sequenced to auto-on via forklift-traffic sensors (not door sensors). Each motor pushes 4,200 m³/h with 1500W draw. Total install: 4,500W vs avoided HVAC over-run of ~14,000W.
18-month tracking: 31% HVAC power saved, 68% dust drop
HVAC sub-meter logged a 31% reduction in chiller load over 18 months of post-install operation, compared to the same months in the prior year (weather-normalised). Particulate count quarterly averages dropped from 168 μg/m³ to 54 μg/m³. Quality rejection rate fell from 3.2% to 1.1%.
Exactly what was installed
Full bill-of-materials with HSN codes, GST-billed and warranty-tracked.
Sanjay didn't pitch — he stayed for a full shift, watched our forklifts and our QC rejection logs side-by-side. The proposal came with regression data, not marketing claims. That's when we paid the advance.
Frequently asked questions
Direct answers from our project engineers.
How do you measure "power saved"?+
Will 3 units handle a 7.5m loading bay?+
What's the typical payback period?+
Can you retrofit during plant shutdown?+
Loading bay leaking your HVAC budget?
Our manufacturing vertical does a full-shift diagnostic before quoting. We bring sub-meters, particulate counters and 16 years of plant-floor HVAC data. No pitch — just regression analysis.
Book Plant-Floor Diagnostic →