How Symphony Venti Cool Improved Yarn Quality and Workforce Productivity at Borana Weavs

Project Snapshot

Challenge

Borana Weavs, a specialist air-jet textile unit, was facing a convergence of operational problems rooted in a single cause — high temperatures and excessively dry air on the production floor. Air-jet weaving is particularly sensitive to atmospheric conditions: dry air causes yarn to lose tensile strength and become brittle, leading directly to breakages during the weaving process. At Borana Weavs, yarn breakage rates had risen by approximately 20%, triggering frequent machine stoppages, missed production deadlines, and growing customer dissatisfaction.

The human impact was equally significant. Workers were struggling to maintain efficiency in the hot, uncomfortable environment, with productivity running approximately 15% below expected levels. Absenteeism increased, and floor morale declined — compounding an already strained production environment. The situation demanded an immediate cooling and humidity management intervention that was scalable to the size of the production floor.

Solution

Symphony Venti Cool conducted a detailed airflow analysis of Borana Weavs’ production floor to determine optimal unit placement for uniform temperature and humidity distribution. Based on this assessment, 48 VC25U air cooling units were selected and strategically installed across the production area. The VC25U was specifically suited for this application given its ability to not only reduce temperature but also add controlled moisture to the air — directly addressing the dry atmospheric conditions responsible for yarn brittleness.

Installation planning was carried out in close coordination with Borana Weavs’ technical staff to minimise production downtime during deployment. Unit positions were mapped to ensure complete floor coverage, eliminating hot spots and dry zones that could trigger localised yarn breakages. The system was commissioned and validated before full production resumed, ensuring no operational risk during the transition.

Performance

The impact of the VC25U installation on the production floor was measurable and rapid. Temperature levels across the weaving area stabilised within an optimal range, and humidity levels rose to suit the moisture requirements of air-jet textile operations. Yarn breakage rates, which had been a persistent operational problem, dropped by approximately 35% — a direct outcome of the improved atmospheric conditions that restored yarn flexibility and tensile strength.

Worker performance responded positively to the cooler, more comfortable environment. Productivity levels climbed by over 20%, and machine uptime improved as stoppages related to yarn breakage became significantly less frequent. The VC25U units operated consistently across all shifts, delivering uniform cooling and humidity control without fluctuation throughout the working day.

Result

The full deployment of 48 VC25U units at Borana Weavs delivered results across every measurable dimension of the operation. Overall production output increased by 15%, enabling the company to meet its order commitments without delays. Fabric quality improved, leading to fewer rejections and stronger customer satisfaction scores. Worker attendance stabilised as improved floor conditions reduced absenteeism and boosted team morale.

Borana Weavs formally acknowledged the contribution of Symphony Venti Cool’s solution to stabilising their production, protecting product quality, and creating a sustainable working environment. The project is a clear demonstration of how precision-deployed evaporative cooling can address both operational and human challenges within the textile manufacturing sector.

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