Cooling solution for a Textile Industry Borana Weavs - Surat

Challenge:

Borana Weavs, a well-known air-jet textile unit, was encountering serious operational challenges due to extremely high temperatures and a dry atmospheric environment inside their factory. The issues they faced included:

• Frequent yarn breakages during the weaving process (up to a 20% rise) because the dry air caused the yarn to become brittle.
• Decreased worker productivity (around 15% lower) as employees struggled to work efficiently in the hot, uncomfortable conditions.
• Production downtime due to frequent machine stoppages related to yarn breakage, leading to missed deadlines and customer dissatisfaction.
• Worker absenteeism and low morale, further aggravating the production challenges.

Cooling solution:

Understanding the critical situation, we proposed a comprehensive aircooling solution tailored to their needs.

• 48 Symphony VC25U air cooling units were strategically installed across the production floor after detailed airflow planning.
• Placement was designed to ensure uniform cooling across the entire workspace, maintaining optimal temperature and increasing humidity levels to suit air-jet textile requirements.
• Our installation team worked closely with the Borana Weavs technical staff to minimize installation downtime and ensure smooth integration without affecting ongoing production.

Outcome & Result:

Following the installation:

• Yarn breakages reduced by approximately 35%, drastically improving the quality and consistency of the fabric produced.
• Worker productivity increased by over 20%, as the cooler environment enabled workers to perform their tasks comfortably and efficiently.
• Overall production output rose by 15%, helping the company meet its order deadlines without delays.
• Worker satisfaction significantly improved, resulting in better attendance and reduced absenteeism, contributing to a stable workforce.
• Quality of yarn strength and final textile finish enhanced, leading to fewer rejections and greater customer satisfaction.

Borana Weavs expressed high satisfaction, confirming that the Symphony air cooling systems played a key role in stabilizing their production, improving profitability, and creating a sustainable, worker-friendly environment.