From Efficiency To Excellence: How Arunachala Gounder Textile Mill Transformed Energy And Air Quality With Tesco Fanz

With over four decades of textile manufacturing excellence, Arunachala Gounder Textile Mill (AGT), located in Pallipalayam near Namakkal in Tamil Nadu, has steadily evolved into a globally recognised yarn producer. Founded as a family-driven enterprise, the mill has built its reputation on innovation, sustainability and consistent quality. Today, AGT’s yarns are exported across key international markets, including Bangladesh, Egypt, Italy, South Africa, Iran, the United Kingdom and the United States.

AGT’s journey toward enhanced operational efficiency gained momentum following a recommendation from the Indian Texpreneurs Federation (ITF), along with strong feedback from neighbouring mills already using solutions from Tesco Engineering Corporation. What began as a considered upgrade soon turned into a transformative shift across its spinning operations.

Before installation, the plant’s energy consumption stood at 50–55 units per thousand spindles per shift. After integrating Tesco Fanz’s power-saving fans, this reduced to 40–50 units, bringing the mill in line with industry benchmarks. Across both spinning units, 19 fans were installed, resulting in daily savings of 450 units in Unit-I and 650 units in Unit-II.

The real impact, however, is most visible inside the mill. “I’ve been working with AGT for the past 13 years and this is the first time I’ve experienced an atmosphere free from fluff liberation,” says Lingaraja, VP – Operations. “Earlier, during peak summer, our workers’ dress, face and hands would often be covered with cotton particles. Now, the environment is remarkably clean.”

Improved airflow and temperature control have also translated into better production performance. Yarn breakage has reduced from 4 out of 10 to 2 out of 10, an important gain for any spinning mill. Additionally, the need for frequent seasonal blade angle adjustments has been eliminated, with the system running consistently for over one-and-half years without intervention.

Operational efficiency has further improved with zero maintenance requirements, easing the burden on electrical teams. Stable Relative Humidity (RH) levels continue to support a comfortable and productive working environment across the department.

The numbers strengthen the transformation. With CHM levels reaching 50,000 in exhaust and 20,000 in supply, AGT now achieves daily energy savings of around 1,100 units. This translates into an annual saving of approximately Rs 38 lakh, delivering both economic and environmental value.

The return on investment has been equally compelling. The cost of installation was recovered within just two months, after which the savings directly contributed to profitability. “With the unit rate rising from Rs 9.14 to Rs 9.50 and expected to increase further, the Tesco fan installation remains one of the most beneficial and sustainable projects undertaken at AGT,” adds Lingaraja.

For AGT, this transition goes beyond efficiency, it represents a strategic step toward cleaner production, improved worker well-being, and long-term sustainability, reinforcing its position as a forward-looking leader in the textile industry.