From Trial To Transformation: How Santhi Processing Unit Achieved Significant Energy Savings With Tesco Fanz

Situated in Pallipalayam on the outskirts of Namakkal district, Santhi Processing Unit Pvt Ltd was established in 1983 by S. Duraisamy, with its headquarters in Erode. Over the decades, the company has steadily expanded its footprint, with branch offices in Bangalore, Delhi, Chennai and Indonesia, reflecting its strong growth trajectory in the textile sector.

With an annual production capacity of 360 lakh metres of fabric, the company’s high-quality woven fabrics are exported to key global markets, including the U.S., U.K. and Europe, highlighting its commitment to quality and international standards.

A key turning point in its operational efficiency journey came through a recommendation from the Indian Texpreneurs Federation (ITF). Prabhu Damodharan from ITF introduced the company to energy-saving solutions from Tesco Engineering Corporation, highlighting their advanced humidification fans designed with a strong focus on power efficiency. He advised a trial-first approach, allowing mills to evaluate performance before scaling implementation.

Following this recommendation, Santhi Processing installed a single fan on a trial basis. The results were immediate and impactful. Within the very first hour, the unit demonstrated power savings equivalent to 48 units per day. Encouraged by this performance, the company monitored the system over a one-month period, after which the results proved highly convincing, leading to the replacement of 22 fans across its units.

The transition delivered substantial gains in energy efficiency. Prior to installation, the spinning unit’s humidification plant consumed around 4,000 units of power per day. Post-installation, this figure reduced significantly to between 2,800 and 3,000 units daily.

Highlighting the broader significance of these savings, M. Venkateswaran, GM – Spinning, remarked, “Energy is a national resource. The 1,056 units we save are not just ours, they benefit the nation as a whole.”

Beyond energy savings, the company has also experienced consistent operational reliability. “So far, we haven’t faced any maintenance issues. Tesco fans are truly maintenance-free and the relative humidity (RH) level is well maintained, which is exactly what every spinning mill expects,” said Gavaskar, Electrical Engineer. “We strictly follow Tesco’s maintenance guidelines and the fans have continued to deliver consistent and reliable performance.”

This successful adoption highlights how a strategic, trial-based approach combined with the right technology can deliver measurable efficiency gains, improved process stability, and long-term sustainability for textile manufacturers.