Citizen Industries

Reducing AHU Components, Increasing Energy Efficiency

CLIENT

Citizen Industries Limited (Ahmedabad, India)

CHALLENGE

  • Plug fan wheels for AHU
  • Increased energy efficiency

SOLUTION

Switched to D-Series Dclassic fan wheels in AHU

RESULTS

  • Reduction of fan wheel variety by 90%
  • Energy efficiency of fan wheels for AHUs increased by 5%

Project Overview

Citizen Industries Limited has been a leading manufacturer of Air Handling Units (AHU), Lab furnishing equipment and Biotech equipment in India for three decades. In 2016, punker helped Citizen reduce the number of different fan wheels used in their AHUs by 90% to only 19 by switching to the punker D-Series.

Streamlining the vast number of components used in their products saved our client time and money and, at the same time, made the Citizen Air Handling Units even more efficient – helping their clients save operating costs in turn.

Our Client

Citizen Industries Limited was established in 1987 with its headquarter in Ahmedabad, India. The company is a leading manufacturer of Air Handling Units (AHU), Lab furnishing equipment and Biotech equipment in India. They serve renowned goverment, public sector or privat company clients  from various industries such as Agriculture, Education, Food & Beverage, Health Care, Pharmaceuticals, Petroleum Industry, or Textiles and Garments. Citizen sets a high value on designing energy efficient, low maintenance and highly reliable HVAC equipment.

Challenge

Citizen Industries and punker had been working closely for more than 23 years in selecting the optimal fan wheels for each AHU requirement, always aiming for maximum energy efficiency. This lead to a large fan wheel variety, as for each project, the optimal fan wheel execution of width, hub, bore and inlet cone was selected. In total, punker supplied 205 different variations of the HLS 70, HLR 70,  and R63D2 series, as well as another 69 corresponding inlet cones. The administrative effort of product drawings and technical documentation, as well as the production and transport time, grew with the number of different items.

Citizen started to look into the option of building their own plug fans instead of purchasing them from a supplier. The goal was to offer a high efficiency plug fan that could be installed in any future air handling project, irrespective of the required air flow and pressure requirements.

  • Supply fan wheels for new AHU plug fans
  • Increase overall system efficiency
  • Reduce overall lead times and inventory of varied items

Solution

punker felt they could support this challenge with the then newly introduced fan wheel series Dclassic. Dclassic is a highly standardized fan wheel series specially designed for use in plug and plenum fans for air handling and ventilation units. The mechanical efficiency static of 75% is perfectly suited to exceed our client’s  energy efficiency requirements. The Dclassic works best in a pressure range from 1.500-2.500 Pa (6 – 10 in. WG – AMCA Class II) and is available in a diameter range of 225 – 1000 mm (9″ to 39 3/8″). This welded steel design with a maximum tip speed 75 m/s (246 fps) is powder coated by default. The well proven Taperlock hub system makes it compatible with any shaft motor option. The use of VSD (variable speed drive) allows for actuating various operating points.

punker introduced the concept of this new fan wheel series to Citizen and presented an analysis showing that the future use of Dclassic fan wheels could eliminate 80% of the article variety that Citizen had bought from punker over the past 20 years. In combination with supporting services from punker, such as a customized DLL file with performance data for Citizen’s own AHU configuration software, the use of Dclassic would allow for a straightforward plug fan design. punker supplies the Dclassic fan wheels with a corresponding inlet cone for optimum air flow. The inlet cone ED 11 is equipped with a connector for airflow measurement by pressure tap, allowing for easy monitoring and adjustment of the AHU’s system performance.

A comparison of the performance curves of previously used fan wheels and the Dclassic showed an increase in static efficiency of up to 5%.  Sample wheels of different widths were supplied for comparison measurements at the Citizen works, which confirmed the calculated performance. Our client thus completed the design of their future plug fans and place the first order of Dclassic fan wheels.

Citizen places orders with variable quantities, based on the demand for each respective AHU project. Due to the standardized character of the Dclassic fan wheel series, punker can deliver them in short cycle times, optimize shipping volumes and container loads according to demand, and provide safe packaging for sea transport.

The switch to the Dclassic fan wheels offered another substiantial advantage for our client: Citizen now sources only 19 different fan wheels from punker, which reduces the number of different components by 90%.

Opinions

Our main objective was to design our own plug fan and increase the system efficiency of our Air Handling Units. On top of that, we reduced our component variety to a sizable quantum which helped us save time and inventory carrying cost.

Kamalesh MehtaCEO | Citizen Groupwww.citizenindia.com

A standardization like this leads to a WIN-WIN-situation for both the customer and manufacturer side: fast availability, cost-efficiency, reference diversity, etc. With this in mind, the development of the D-Series had two main objectives: 1) Standardization 2) Simultaneous opportunity of a new development according to the highest technological requirements.

Juergen BeinkeGlobal Sales Director (CEO) | punker Group

punker D-Series

The punker D-Series was designed with similar needs in mind, always aiming for maximum energy efficiency. The D-Series’ four models of fan wheels are suitable for use in any unhoused HVAC application by meeting different static pressure requirements ranging from 1.000 to 4.500 Pa (4 to 16″ WG) and delivering volume flows of up to 70.000 m³/h (41.200 cfm). Flexible motor mounting options make these fan wheels compatible with both AC and EC motors with or without variable speed drive (VSD). The D-Series is the perfect fit for both newly built and retrofit air handlers.