Our Projects/Automotive Manufacturing/Hero MotoCorp
Automotive Manufacturing
WEI designed and implemented its Bigfoot ductless HVAC system for Hero MotoCorp’s Neemrana, India plant, integrating building pressurization, humidity control, condensate reuse, heat-pump operation and Global Controls.
Hero MotoCorp’s Garden Factory was conceived as an intelligent workplace combining nature and technology. The Neemrana climate posed a hard HVAC challenge: long, dry summers followed by monsoons with extremely high humidity.
It had to maintain comfort and air quality while limiting dust and contaminants, controlling humidity and supporting the Garden Factory’s environmental goals.
After seeing WEI’s Bigfoot ductless HVAC running at a Ford plant, Hero MotoCorp asked WEI to design and implement it at its new India facility.
WEI designed two 200,000-CFM Bigfoot units to pressurize a 300,000-square-foot area. Positive building pressure distributes conditioned air, eliminating conventional ductwork while limiting dust and outside contaminants.
It combines ductless pressurization, heat-pump chiller operation, humidity control and real-time fresh-air calibration for comfort and efficiency in a large manufacturing environment.
Hero MotoCorp’s bio wall of oxygen-producing plants is integrated with the HVAC strategy, reducing outside-air ventilation while Global Controls monitor oxygen levels and calibrate fresh-air demand.
In high humidity, Bigfoot reclaims cooling-coil condensate to water the green wall and mist the air-cooled chiller condensers. When reheat is needed for temperature and humidity, it runs a heat-pump chiller to maximize efficiency.
Cooling-coil condensate is reused for the bio wall and for condenser-coil misting during humid conditions.
Oxygen levels and fresh-air requirements are monitored so ventilation can be calibrated to actual facility conditions.
WEI’s Bigfoot design and implementation reduced energy costs by 30% while improving environmental conditions inside the plant.
Humidity control and non-stratified air increased electronic-equipment lifetime by 70%, while better air quality cut employee health concerns by 90% and supported retention and productivity.
The partnership helped Hero MotoCorp earn the 2016 TIME India Manufacturing Innovator of the Year award. Hero MotoCorp has continued working with WEI on integrated HVAC for greenfield projects and retrofits of older plants.
ENGINEERED. INSTALLED. VERIFIED.
WEI integrates air distribution, controls, heat recovery and facility conditions into one operating strategy.
