Lumax India Limited
Overview
Lumax India Limited is a leading automotive component manufacturer specializing in lighting systems for major automobile brands. The Sanand plant in Gujarat focuses on high-precision plastic molding and assembly for automotive headlight manufacturing, where maintaining temperature stability and air quality is crucial for process accuracy and product finish.
Project Requirement
The client approached Weather Controlling Solutions India Pvt. Ltd. (WCSIPL) to design and install an efficient air conditioning and cooling solution for their molding and production areas. The requirement was to maintain a consistent and clean environment to ensure defect-free molding and assembly operations. The target was to achieve a comfortable working temperature below 30°C despite high ambient and equipment heat loads.
WCSIPL Solution
WCSIPL provided a hybrid cooling system combining precision air conditioning with energy-efficient evaporative cooling. The system included two air-cooled chillers, each of 200 TR capacity, along with a two-stage evaporative cooling system designed to handle 300,000 CFM of treated air. The solution was engineered to maintain uniform temperature and humidity across the large production floor while minimizing power consumption.
System Configuration
- Two (2) Nos. Air-Cooled Chillers – 200 TR each
- Two-Stage Evaporative Cooling System – 300,000 CFM
- Centralized Air Handling Units (AHUs) for uniform air distribution
- Energy-efficient centrifugal and axial fans
- Dedicated process air zoning for molding and finishing areas
- Advanced control system with centralized monitoring for temperature, humidity, and air flow
Results Achieved
The implemented system successfully maintains process area temperature below 30°C, ensuring stable operating conditions for plastic molding machines and improving product quality. The hybrid solution resulted in over 65% energy savings compared to conventional air conditioning systems. Operators also reported improved comfort levels and reduced equipment downtime due to better environmental control.
Key Highlights
- Industry: Automotive Lighting (Plastic Molding)
- Location:Sanand, Gujarat
- Cooling Capacity: 400 TR (2 x 200 TR Air-Cooled Chillers)
- Air Volume: 300,000 CFM (Two-Stage Evaporative Cooling)
- Energy Savings: Approx. 65% over conventional AC
- Scope: Turnkey HVAC Design, Supply, Installation & Commissioning
- Executed by: Weather Controlling Solutions India Pvt. Ltd. (WCSIPL)
Conclusion
The Lumax Sanand plant project exemplifies WCSIPL’s expertise in delivering industrial HVAC solutions that combine technology, energy efficiency, and reliability. The two-stage evaporative system coupled with a high-capacity chiller plant demonstrates an optimal balance between process comfort and cost-effectiveness for large-scale plastic molding operations.