How Evaporative Venti-Cooling Restored Productivity Across WelSpun Textiles’ Multi-Location Plants?

Project Snapshot

Client	WelSpun Textiles
Industry	Textile Manufacturing
Locations	Vapi, Hyderabad & Kutch
Facility Size	5,000 sq. ft. (Vapi production site)
Units Installed	5× PAC25U (Vapi) + Additional Units (Hyderabad, Kutch)
Post-Cooling Temp	32–35°C at Vapi production site

Challenge

WelSpun Textiles, one of Gujarat’s prominent textile producers with facilities in Vapi, Hyderabad, and Kutch, was facing a significant decline in both productivity and workforce health across its production sites. Rising indoor temperatures at the manufacturing floors were making working conditions increasingly difficult, with workers unable to sustain performance levels during extended shifts. The problem was consistent across locations and required a scalable solution that could be standardised across all facilities.

Vapi — widely known as Gujarat’s paper and textile hub — posed the most immediate concern. The production site there spans approximately 5,000 sq. ft., and the heat buildup across this area was directly impacting machine efficiency and worker output. Management needed a phased, data-backed approach to cooling that could be validated on-site before full-scale deployment.

Solution

Symphony Venti Cool’s team assessed the Vapi production site and recommended a phased installation approach. In the first phase, one PAC25U duct air cooler was installed to evaluate performance in the actual working environment. The PAC25U was selected for its top-and-down discharge capability, which enables efficient air pumping across large floor areas — critical for a 5,000 sq. ft. production space.

Following positive worker feedback and measurable temperature reduction, four additional PAC25U units were installed at the Vapi site, bringing the total to five. The same solution was subsequently deployed at WelSpun’s Hyderabad and Kutch facilities, which reported identical heat-related challenges. The PAC25U’s key technical advantages made it the appropriate choice across all three locations:

• Top and down discharge ducts for efficient air coverage in large spaces
• Plastic construction enabling quick and easy installation with minimal downtime
• Optimised motor for powerful airflow with low operational noise
• Consistent standard airflow speed without fluctuation across shifts
• Built-in filters to protect and extend the life of cooling pads
• Robust honeycomb pads for superior, controlled airflow performance

Performance

After full deployment at the Vapi facility, indoor temperatures stabilised at 32–35°C — a significant reduction from the pre-installation peak levels that had been disrupting operations. The PAC25U units maintained consistent airflow throughout production hours, with no observed fluctuations in cooling output during high-load periods. Workers reported improved comfort almost immediately following the first phase of installation, which provided the confidence needed to proceed with the full five-unit deployment.

Across the Hyderabad and Kutch plants, the same PAC25U configuration delivered comparable results, confirming the system’s reliability and scalability across different facility layouts. The units required minimal post-installation adjustments and operated efficiently within WelSpun’s existing infrastructure.

Result

The phased deployment across all three WelSpun Textiles locations successfully restored normal working conditions and worker productivity. Daily production output increased following the temperature stabilisation, and workforce attendance and performance improved noticeably. The multi-location rollout demonstrated Symphony Venti Cool’s ability to deliver a scalable, standardised cooling solution across geographically distributed industrial facilities — making it a dependable long-term cooling partner for WelSpun’s operations.