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JK Tyres operates 9 large factories across India as one of the leading tyre manufacturers. The company pioneered radial tyre manufacturing and offers comprehensive vehicle tyre solutions. As energy costs continued to rise and environmental awareness increased, JK Tyres recognised the need for advanced energy-efficient ventilation solutions at their Chennai manufacturing facility.
The existing infrastructure presented several operational challenges:
- Conventional centrifugal fan systems consumed excessive energy
- Extreme operating temperatures reached 46°C during peak summer
- Fixed power consumption limited flexibility in production environments
- Ageing air handling units required modernisation
Technical partnership enabled JK Tyres to implement the most sophisticated energy efficiency solution available. After extensive market research including EC fans, JK Tyres collaborated with Xero Energy Engineering Solutions to deploy the innovative EC+ concept. This integrated system combines high-efficiency ZerAx® fans, premium motors, and intelligent Danfoss VFDs for optimal energy efficiency in process industry applications.
Project highlights
Achieved over 50% reduction in energy consumption, exceeding the initial 30% target at Chennai facility
Complete EC+ system delivers efficiencies up to 85%, the highest achievable total system efficiency for industrial AHUs
ZerAx® fans operate reliably in extreme temperatures reaching 46°C during peak summer with near-continuous operation
JK Tyres becomes Asia's pioneer in EC+ concept implementation, leading the region in advanced energy efficiency technology
First EC+ deployment delivers 50% reduction
This marks the first EC+ concept implementation in India, making JK Tyres Asian pioneers in this technology. The complete system delivers efficiencies up to 85% - the highest achievable total system efficiency for AHUs in industrial applications. Advanced EC+ concept technology convinced JK Tyres to retrofit existing centrifugal fans in their air handling units with high-efficiency ZerAx® axial flow fans, premium motors, and Danfoss variable speed drives.
While targeting 30% energy savings, the Chennai facility achieved over 50% reduction, validating the technology's scalable benefits. This exceptional performance demonstrated the significant advantage of retrofitting centrifugal systems with ZerAx® technology, particularly in demanding industrial environments.
ZerAx® retrofit operates at extreme temperatures
As India's first manufacturer deploying the EC+ concept, JK Tyres retrofitted their existing air handling system at the Chennai facility. The implementation centred on a high-efficiency ZerAx® axial flow fan AZN 900/350‐6, integrated with a premium motor and intelligent Danfoss VFD system.
The solution addresses critical operational requirements in the tread application area. The fan now delivers substantial energy savings whilst supplying ventilation to one of the most demanding production zones. This area operates at extreme temperatures reaching 46°C during peak summer conditions with near-continuous operation requirements, making thermal performance and reliability essential.
50 %
Energy reduction100 %
Fan replacement planned46 °C
Operating temperatureReduced emissions support corporate responsibility
The EC+ technology implementation delivered measurable benefits across multiple performance indicators. Carbon dioxide emissions substantially decreased whilst operator comfort levels were maintained throughout production areas. Equipment reliability improved in extreme temperature conditions.
These results supported JK Tyres' corporate social responsibility initiatives at the Chennai facility. The solution demonstrated that environmental performance and operational efficiency could advance together, because advanced fan technology eliminated the traditional compromise between energy use and ventilation effectiveness.
Reduced emissions support corporate responsibility
The EC+ technology implementation delivered measurable benefits across multiple performance indicators. Carbon dioxide emissions substantially decreased whilst operator comfort levels were maintained throughout production areas. Equipment reliability improved in extreme temperature conditions.
These results supported JK Tyres' corporate social responsibility initiatives at the Chennai facility. The solution demonstrated that environmental performance and operational efficiency could advance together, because advanced fan technology eliminated the traditional compromise between energy use and ventilation effectiveness.
AHUs significantly contribute to Chennai Plant's fixed power consumption. We trialled replacing conventional centrifugal fans with ZerAx axial flow fans and achieved immense power savings whilst maintaining operator comfort levels. Based on recorded savings, we're implementing 100% replacement of existing AHU fans with ZerAx axial fans.
Engineering partnership delivers measurable results for industrial manufacturers. The success at JK Tyres demonstrates how the EC+ concept can optimise facility energy efficiency whilst improving operational performance. Contact the technical team to discuss implementation for your specific requirements.
