Danfoss A/S, Denmark is a manufacturer of mechanical and electrical components and solutions for the refrigeration and air conditioning industry. It is planning to invest Rs. 500 crores over the next three years for an integrated campus for its manufacturing and research & development (R&D) activities at Chennai.
The campus will be spread over 50 acres in Oragadam, an industrial suburb to the west of Chennai. The expansion of its manufacturing and R&D facilities will generate around 2,000 jobs by 2015 in India. The company currently employs around 300 people. India will be the company's manufacturing hub for the Asia-Pacific region and its largest global R&D centre.
Blue Star was awarded the contract of Rs. 29.5 crores for the HVAC works for 11 buildings out of 14, which includes manufacturing, administration and R&D facilities with stringent completion deadlines.
The architect/services consultant for this project is M/s C R Narayana Rao, LLP and the project management consultant is Facilities and Building Solutions (FABS).
Blue Star has booked an order valued at Rs. 13 crores from JCB for their factory at Jaipur. JCB India Limited, Ballabgarh (Haryana) is a fully owned subsidiary of JC Bamford Excavators Limited, UK, one of the world's leading manufacturers of earthmoving and construction equipment. Worldwide, JCB produces over 300 different models, which are sold in over 150 countries.
JCB is constructing a state-of-the-art Green Factory Building at Mahindra World City, Jaipur and aspires to acquire the coveted IGBC Green Factory Building Rating Program. The factory includes the fabrication building, assembly building, utility building, central kitchen building, machine cycle test shed and administration building.
Blue Star's scope comprises supply, installation, testing and commissioning of three units of 175 TR air cooled screw chillers manufactured by Blue Star and air washers at the shop floor level. It also includes low side works for the office area including ducting, piping and electrical works.
The consultant for the project is CP Kukreja & Associates.
Blue Star has booked an integrated MEP order valued at Rs. 28 crores from Dr Oetker for their upcoming factory at Bhiwadi, Rajasthan.
Dr Oetker is a fourth generation family-owned enterprise from Germany, headed now by Dr H C August Oetker. Currently, the Oetker Group is one of Germany's largest fully privately owned diversified industrial groups, with a turnover of €9.2 billion and 25,000 employees. The group has substantial interests in the food sector (of €1.9 billion) with about 300 different products. Other business sectors of the group include beer, banking, logistics, wines and spirits. Over the years, the company has made successful forays into frozen foods, chilled desserts and ready-to-eat mixes, through acquisitions within and outside Germany. Dr Oetker India was established in 2007. In 2008, Dr Oetker India acquired Fun Foods, a leading purveyor of western cuisine in India and thus a perfect match. The product range includes mayonnaises, sauces, spreads, salad dressings, cakes and dessert toppings, amongst others.
Dr Oetker India is constructing a state-of-the-art factory to manufacture their products in Bhiwadi, Rajasthan. The new plant will not only take care of the existing product portfolio, but will also manufacture Dr Oetker's food products, which will be launched in a few months' time.
Blue Star's scope comprises supply, installation, testing and commissioning of three units of 235 TR air cooled screw chillers and associated pumping system, air handling units, ventilation fans, ducting and piping. The scope of electrical works includes two units of 1,600 kVA 33/0.415 kV transformers, three units of 1,010 kVA & one unit of 380 kVA DG sets, LT panels, 33 kV HT panels, HT and LT cables and their terminations, distribution boards, lighting, cable trays and raceways, earthing and LP system, fire suppression system, LV system (fire alarm & PA system), MICC cables, octagonal poles, UPS and others. The plumbing and fire-fighting scope includes supply, installation, testing and commissioning of UL-listed fire pumps, grooved fittings in fire-fighting works, plumbing pumps, WTP, SS and GI piping, hydrant and sprinkler system and accessories, and fire extinguishers, amongst others.
VS Kukreja & Associates is the consultant and the architect/project management consultant for the project is Enar Consultants.
Blue Star has booked an order valued at Rs. 29 crores for the air conditioning of MRF's Ankenpally project in Medak District, Telangana. This is MRF's seventh such facility and is meant for exclusive manufacture of radial tyres.
MRF Limited is an Indian-based company engaged in the manufacturing, distribution and sale of tyres for various kinds of vehicles. The company is primarily engaged in the manufacture of rubber products, which includes tyres, tubes, flaps, tread rubber and conveyor belts. It exports to more than 65 countries.
Blue Star's scope in this 700 TR air conditioning and ventilation order includes the supply, installation, testing and commissioning of 11 air cooled chillers, 23 chilled water pumps, seven air handling units, 50 HP VRF, 15 airwasher systems, fans, associated rectangular and spiral ducting as well as electrical works. The project is slated for completion in seven months.
Good customer relationship and performance coupled with proven technical expertise helped Blue Star book the order.
Semac is the architect and HVAC Consultant for the project, while JLL is the project management consultant.
Blue Star has received an order valued at Rs. 10 crores from Tata Steel, Jamshedpur for their new Pressure Reducing Stations (PRS).
Tata Steel, Jamshedpur, intends to install an automatic scarfing machine in its LD#2 shop. As a part of this augmentation scheme, to meet the peak flow requirement, PRS for oxygen, nitrogen and propane are required.
In the project, Blue Star's scope comprises design and engineering, supply, erection and commissioning of the system. Additionally, the scope covers the Yard and Shop pipework of oxygen, nitrogen and propane. Blue Star has executed eight other similar PRS jobs at the Tata Steel, Jamshedpur plant.
MN Dastur & Co. Pvt. Ltd. is the consultant for the project.
Blue Star has been awarded an order valued at Rs. 6.4 crores by Tata Steel Limited for air cooling systems at their Digwadih Colliery, Jharia Division, Dhanbad in Jharkhand.
Underground mines at Tata Steel, Jharia are the first in the country to get ISO 14001 certification for attaining the desired standards in mining operations, quality production, coal beneficiation, captive power generation and environment management. Since 1910, the Jharia coalfields have been fulfilling the coal needs of Tata Steel. The Division is capable of producing over 1.6 million tonnes of raw coal from its underground mines, which are more than 600 metres deep and have a gradient of upto 1:4 in places.
Air conditioning works in these settings are quite challenging given the fact that the whole system has to be designed to suit underground installation with most of the components required to be flame-proof and explosion-proof, complying to stringent specifications to be approved by the Directorate General of Mines Safety. Transportation of equipment, their installation and connectivity works to be executed in the gaseous atmosphere of the mines are challenging and demand close attention to detail.
The air conditioning scope of the project includes supply, installation, testing and commissioning of four 165 TR water cooled screw chillers, chilled water & condenser water pumps, plate-type heat exchanger and flame-proof AHUs, among others.
The scope also includes air distribution through a huge piping network with ancillaries and related electrical works.
National Mineral Development Corporation (NMDC) Limited is a state-controlled mineral producer, owned by the Government of India and under administrative control of the Ministry of Steel.
It is involved in the exploration of iron ore, copper, rock phosphate, limestone, dolomite, gypsum, bentonite, magnesite, diamond, tin, tungsten, graphite and other minerals.
NMDC is India's largest iron ore producer and exporter, producing about 30 million tonnes of iron ore per annum from three fully mechanised mines in Chhattisgarh and Karnataka.
Blue Star has received an order valued at Rs. 56.5 crores from NMDC to set up two compressed air stations (CAS 1 & CAS 2).
CAS 1 will provide industrial air as well as instruments air to the raw material handling system, coke oven, by-products, sinter plant, blast furnace, lime and dolo facilities.
CAS 2 will provide industrial and instruments air to the steel melting shop, thin slab caster, hot strip mill, oxygen plant and other auxiliary facilities of the steel plant.
The scope of the project includes design and engineering, supply, installation, testing and commissioning of an air drying unit to provide dry compressed air for industrial purpose as well as for the instruments at NMDC's new 3 MTPA integrated steel plant at Nagarnar in the state of Chhattisgarh.
The consultant for the project is MECON.
Blue Star has booked an order worth Rs. 7.5 crores from MRF for HVAC works at their existing plant in Tiruchirappalli, Tamil Nadu.
MRF is primarily engaged in the manufacture, distribution and sales of tyres for different types of vehicles. In addition, they also manufacture a wide range of other rubber products such as tubes, flaps, tread rubber and conveyor belts. The company exports its products to more than 65 countries.
The scope of the project includes HVAC works comprising supply, installation, testing and commissioning of air washer units, ventilation fans and hood exhaust ducting.
Good customer relationship and performance coupled with proven technical expertise helped Blue Star book this repeat order. In the past, Blue Star has executed a HVAC job valued at Rs. 26 crores for MRF's Ankenpally plant in Hyderabad.
The architect and HVAC consultant for the project is Semac, while JLL is the project management consultant.
Madras Rubber Factory, or MRF, is the largest tyre manufacturer in India, with its headquarters in Chennai, Tamil Nadu. MRF also produces rubber products like treads, tubes, conveyor belts, as well as paints and toys.
The Trichy plant is a significant expansion project of MRF and will be one of their biggest plants in India. Capacities of MRF truck and bus radial tyres and passenger car radial tyres will be enhanced once this plant is commissioned.
The consultant for this project is L&T Technology Services and the PMC is JLL.
MRF is already a prestigious customer of Blue Star, having completed many of their projects earlier in South India, including at Trichy, Pondicherry, Ankenpally and Medak.
Blue Star has now received two orders for services at the new project site too, worth over INR 40 crores. The first order was for air conditioning works including complete high and low side works worth INR 27 crores, and the second one was for ventilation works worth INR 13.5 crores.
The scope of the air conditioning order includes: High Side Work: Complete plant rooms works consisting of three 500TR chillers, three 250TR chillers, 12 pumps, expansion tanks, etc. Low Side Work: 26 AHUs, three dehumidifiers for the Creel Room, 120 air curtains, PVC strips, eight IEC61439 panels, 20,000 sq m of ducting, 2.9km of piping, 41km of cabling, PLC system, etc.
The scope of the ventilation order includes: The Supply, Installation, Testing, and Commissioning (SITC) of nine air washers, 75 ventilation fans, exhaust hoods, 25,000 sq m of ducting, 15,000 sq m of insulation, 46HP of VRF units, 11 IEC 61439 electrical panels, 31km of cables, and 4,400m of cable trays, along with related low side works.
This is a fast-track project with a tight delivery timeline. The delivery of the chillers and PLCs will be critical to meeting this deadline and is the main challenge at this site.Blue Star’s MEP group takes pride in its project management expertise. The experienced teams, their attention to detail, and the use of cutting-edge technology enable the company to efficiently complete projects on time and meet or exceed client expectations. At the MRF site too, effective use of project management delivery tools like project scheduling software, risk management, and supply chain management will ensure fast-track project delivery despite tight deadlines. By leveraging these tools, Blue Star is able to track progress, identify potential delays, and mitigate risks in real-time. We placed an early order on Chillers, VRF, and Airwashers, ensuring the timely delivery of critical equipment for commissioning the Air conditioning and Ventilation systems. Since both the Chiller & VRF were of Blue Star make, we had better control of the lead time of this equipment’s by maintaining a high level of coordination with our factory team. This, in turn, will result in precision, efficiency, and a methodical approach to materials planning, project management, and coordinated activity overall.
The Freudenberg Group is a German family-owned diversified group of companies whose products include housewares and cleaning products, automobile parts, textiles, building materials, and telecommunications. Its headquarters are in Weinheim, BadenWürttemberg, and it has production facilities in Europe, Asia, Australia, South and North America. This new factory of the group, coming up in the Morinda City of Rupnagar District of Punjab, is designed to be a Platinum IGBC rated production plant. It is slated to be the largest MEP project in the Northern region.
The consultant for this project is Pithavadian & Partners and the PMC is A N Prakash Construction Project Management Consultants Pvt Ltd.
Blue Star received an order worth INR 62.5 crores for the MEP works at the Plant including HVAC, Plumbing and Electrical works.
The scope of the order includes: 4 Chillers, 20 Pumps, 7 Cooling Towers, 20 AHUs, 99 LT Panels, 6 HT Panels, 4 Transformers, 92.2km of cables, 16.2km of cable trays, 1.9km of busducts (Sandwich Type), 7.2km of busducts (Air Insulated Type), 23 UPSs, 9.5km of pipes, and 356 Valves.
The main challenges at this site are that much of the work is at a triple ceiling height, requiring careful planning and safe operations, and a strict delivery deadline of physical installation within 4 months.
Blue Star, with its proven track record of delivering high-quality projects on time even while prioritising safety, has earned a reputation for excellence in superior project delivery and continues to exceed expectations in the factories segment. At this project site too, to handle the risks of working at heights, Blue Star implemented several safety protocols to ensure worker safety, including the use of Personal Protective Equipment, proper harnessing and lanyarding, adequate training, stable scaffolding and platforms, regular inspection, planning and supervision, and emergency response procedures. These safety measures reflect Blue Star’s commitment to both safety and quality, and successful project completion within strict delivery deadlines.
Hindustan Aeronautics Limited (HAL) is an Indian aerospace and defence company, headquartered in Bangalore. It is one of the largest manufacturers globally, involved in designing and manufacturing of fighter jets, helicopters, jet engine and marine gas turbine engine, avionics, software development, spares supply, overhauling and upgrading of Indian military aircraft.
A new helicopter manufacturing facility of HAL is coming up at Gubbi Taluk, Tumkur, Karnataka. HAL plans to manufacture 100 helicopters per year in this facility and export to other countries.
Blue Star received the prestigious order for the HVAC and Electrical services at the new facility. The order is worth INR 26.91 crores.
While HAL is the end customer, Blue Star received this order through General Contractor P&C Projects Pvt Ltd. This is a repeat order for Blue Star from P&C Projects after successful execution of their earlier projects at Chennai and Kannur. Central Public Works Department (CPWD) is monitoring this project on behalf of HAL.
The scope of the order includes Blue Star make chillers & VRFs: 240TR x 3 screw and 60TR x 3 scroll chillers, 450HP VRF, 53km of cabling, 3500 light fixtures, and HT & LT works.
Blue Star’s scope also includes detailed design and installation of HVAC & Electrical works of 18 isolated blocks which includes critical areas like hangers and paint shops.
Challenges at site are manpower mobilisation and the fact that there are two approval authorities: CPWD and HAL.
Blue Star efficiently managed the challenges relating to manpower mobilisation by streamlining the recruitment process, besides providing necessary training and development opportunities for the employees. Besides, clear communication channels were established with both CPWD and HAL, which resulted in effective handling of all stakeholders, a collaborative approach, and timely processing of approvals, resulting in superior project delivery within set deadlines.
Page Industries Limited, the exclusive licencee of Jockey International Inc (USA) for the manufacture, distribution and marketing of the Jockey® brand in India, Sri Lanka, Bangladesh, Nepal and the UAE, is setting up a new manufacturing facility at Cuttack, Odisha. Designed as a Platinum IGBC rated manufacturing hub for Innerwear & Socks, the new facility, spreading over 6.5 lakh sq ft, is the first one that is being built to such a large scale in the eastern part of India.
The Consultant for this project is C R Narayana Rao of Chennai, while the PMC is JLL and Architect is from Page Industries’ own internal team. The integrated MEP services for the site, which included HVAC, Fire-fighting and Electrical services, was awarded to Blue Star, through an order worth Rs 51 crores.
Blue Star’s vast experience in this line, smooth coordination between different teams and efficient project management resulting in superior project delivery, and commitment to delivery despite tight deadlines, helped Blue Star receive this prestigious order.The order includes a range of equipment and materials for air conditioning, including 2650TR of air conditioning, 5 cooling towers, 46 AHUs, 20 pumps, 35,000 sq m of ducting, 30km of piping, 3200RMT of busduct, 1.6L RMT of cables, and 25,000RMT of cable trays. These items will be used for comfort cooling in some areas and process cooling in others, with the goal of maintaining a temperature of 27±1 °C in process cooling areas and 24±1 °C in comfort cooling areas. The order also includes associated low side works.
Every site presents its own unique challenges, and the Jockey factory is no exception. However, Blue Star has tried and tested systems in place to handle such hurdles routinely and professionally. At this site, for example, many portions of the facility have ceilings at a height of 12m, giving rise to safety risks while working at heights. Besides, a 12m-long pipe needs to be moved to the site and over 300 workmen need to be mobilised during certain phases of the execution.
Blue Star’s adherence to safety processes and protocols, and expertise in logistics and man-management, will ensure that the Company can handle these challenges successfully and without causing any delays to the delivery of the project.
Wipro Hydraulics, the hydraulics business of Wipro Infrastructure Engineering (WIN), specialises in the design and manufacture of custom-built hydraulic cylinders for applications in diverse segments of construction, earthmoving, material & cargo handling, forestry, farm & agriculture, mining and truck tipping. With over four decades of engineering and manufacturing experience, Wipro Hydraulics is amongst the largest independent hydraulic cylinder manufacturers in the world, and a leading hydraulic solution provider to global OEMs. The company has a cross-continental geographical presence across India, Europe, USA and Brazil, with 11 state-of-the-art manufacturing facilities.
Wipro Hydraulics’ latest plant is coming up in Mahindra World City, Jaipur, Rajasthan, for which the PMC & Consultant is CP Kukreja Architects.
Blue Star has been awarded the order for execution of the Electro Mechanical Works at the new factory. The order comprises MEP Works including Electrical, HVAC, and Fire-Fighting, and is valued at Rs 26 crores.
The detailed scope of the order includes 38 LT panels, over 59km of cabling, 8.6km of cable trays, 148 distribution boards, one 33kV HT panel, 261m of bus duct, two transformers, 8.6km of fire survival cabling, two air cooled 120TR screw chillers with adiabatic kit, eight pumps, one 80kW heat pump, 23 AHUs, 13 air washers, six sets of pumps, one pump panel, gas suppression system, 48 extinguishers, hydrant system, 594 sprinklers and more.
The main challenge facing Blue Star at this site is the tight timelines given for completion of the project. However, Blue Star is well equipped to handle this challenge and plans to mobilise the higher numbers of manpower required to ensure completion of all work on time. Safety standards at site are also set by the client at very high levels but Blue Star is confident that its own internal safety processes are adequate to cater to the client’s demands in this regard.
Blue Star enjoys a favourable relationship with the client and fully expects to deliver on its promise of ‘superior project delivery’ and ensure high levels of client satisfaction. This will ensure that future MEP orders from Wipro Hydraulics will continue to be awarded.
Maruti Suzuki is one of the premier automobile manufacturers in India. It is a subsidiary of the Japanese auto maker Suzuki Motors and holds a market share of over 40% in India. Cars from Maruti Suzuki are well known for their quality, reliability, and fuel-efficiency, and are most sought after by the Indian consumer.
Maruti Suzuki plans to add to their existing capacity with a new plant at Kharkhoda, Sonipat, which is in Haryana, just north of New Delhi. Spread over 800 acres, the new Kharkhoda plant will have an annual capacity of 2.5 lakh vehicles. The first Maruti Suzuki model is slated to roll out from here in 2025.
Blue Star is proud to have received an order for a portion of the work to be done at the new plant. An order worth Rs 59.26 crores for ‘Package-01 (VEH)’ which is for the supply and installation of low side utility piping work for Phase 1 (shops, utilities and other areas) of the Kharkhoda plant, was awarded to Blue Star.
The detailed scope of the Utility Piping order includes 103 km of piping, 33,960 pipe fittings, 7,178 valves, 102 pumps, 87 flow meters, 5 intelligent flow controllers, and 19,000 sq m of painting.
The main challenge that Blue Star will face at this site is the large manpower of 350 to 400 workmen who will need to be deployed at any point in time. With Blue Star’s decades of experience in this activity, the Company is confident of managing the challenge comfortably and handing over the site on time to the client. Blue Star is adopting modern site practices to ensure professional, precise and efficient site management while executing this project.
This is Blue Star’s second order from Maruti Suzuki. With the ‘superior project delivery’ promise, Blue Star expects to deliver this project too to the entire satisfaction of the client, which could open up possibilities for future orders worth over Rs 200 crores over the next five years, from the client’s upcoming expansion projects.
Tata Electronics Private Limited (TEPL) is a greenfield venture of the Tata Group, which is into the manufacture of electronics ancillaries and precision components, especially the manufacture of mobile ancillaries. TEPL plans to expand its present set up at Hosur, named ‘Project Marigold’, which is expected to be one of the largest precision engineering and manufacturing plants in India today.
The PMC for the project is TCE, while the MEP Consultant is Esollutions, and the Architect is Venkatraman Associates.
Blue Star has been awarded the order worth Rs. 108 crores for HVAC and Electrical Works at the new plant. The order includes the air conditioning and electrification of the Production block, the Quality Control Lab (which is a Clean Room), the dining halls, office areas, UPS and electrical rooms, server rooms, and the utility building.
The site poses several challenges for Blue Star’s teams. Firstly, the project demands completion within a stringent timeline of less than 5 months, requiring substantial manpower deployment. Additionally, project involves long lead items such as AHUs and ventilation units with EC fans and pumps and cooling towers with IE4 motors. Moreover, extensive ducting and cabling inside factory area and pipe works in trenches are time consuming.
Blue Star is confident of overcoming these challenges. The company’s experience in mobilising manpower will help to ensure swift completion of the work. To expedite delivery, careful vendor evaluation and order placement with those having ready stocks are being prioritised, especially for the EC fans and IE4 motors. For faster piping and ducting, pre-engineered supports are being used extensively. To accelerate the execution, the strategy includes contracting a minimum of two vendors for low side work such as ducting and cabling. Furthermore, overcoming the challenge of pipe welding is planned through the use of couplings and flange joints, enabling quicker installation.
Blue Star’s proven track record of superior project delivery, exemplified by its successful completion of HVAC works in the Assembly Building on the same campus, played a pivotal role in securing this second order for HVAC and Electrical works during the plant expansion. With unwavering determination and expertise, Blue Star is well on its way to delivering exceptional results in the timely and efficient execution of this project - another testament to its excellence in the industry.
ST Telemedia (STT) is a Singapore-headquartered strategic investor specialising in Communications & Media, Data Centres and Infrastructure Technology businesses globally. It is represented in 15 countries and 3 continents across the Asia Pacific, the US and Europe. STT’s new data centre project coming up in the city of Pune, Maharashtra, is designed to be a Gold IGBC rated data centre. The building will have a built-up area of 22,722 sq m.
The design consultant for this project is AECOM and the PMC is JLL.
Blue Star received an order worth INR 260 crores for General Contracting of Civil, Interior and MEP works at this project. This is not Blue Star’s first order from STT. Over time, Blue Star has become a trusted partner of STT due to MEP expertise and rapport with the client based on earlier project execution experience at STT DC Noida. Post this order, Blue Star has also received a repeat order worth INR 110 crores for STT DC Noida Phase II.
The scope of the order includes: Construction of Data Centre building and DG building, HSD system, infra works for compound walls and roads, lifts, interior works, and landscape works; and HVAC, Electrical, Plumbing & Fire-fighting works. Design must be compliant with TIA 942 B standards. Challenges at this site include the high manpower requirement since it is a design and built project, and maintenance of safe working conditions and standards on a continual basis.
Blue Star’s expertise in the design and build of data centres is unparalleled. The unique ecosystem and requirements of these projects demand innovative solutions, and Blue Star has consistently delivered on this front. The Company’s commitment to quality workmanship is evident in its use of a highly skilled workforce, advanced technology, and rigorous quality control procedures, which ensure that projects meet or exceed industry standards and client expectations. One of the biggest challenges at this project site was the high manpower requirement. Blue Star overcame this obstacle by investing in an efficient and skilled workforce and adopting innovative construction techniques to ensure efficiency and speed. The Company also prioritised safety on site, appointing a dedicated team of experts to monitor compliance with safety protocols, conducting regular safety audits and training sessions for the workforce, and using state-of-the-art technology and equipment to ensure safety regulations were followed, even while delivering a superior project well in time!