Achieve up to 55% energy savings in Banbury mixer zones with Airzon BLDC fans.
Understanding Energy Mapping in Tyre Plants
Energy mapping in a tyre plant involves analyzing electricity consumption across production lines from Banbury mixers and curing presses to ventilation systems. Among these, the Banbury mixing section stands out as one of the highest energy-consuming areas. Continuous mixing generates substantial heat, demanding constant airflow to maintain process stability and prevent overheating.
Most conventional fans in these zones operate for long hours, consuming 150–200 watts per unit. Over time, this constant power draw adds up, significantly increasing the plant’s overall energy costs and carbon footprint.
Where Airzon BLDC Banbury Line Mixer Fan Makes the Difference
The Airzon BLDC Banbury Line Mixer Fan is purpose-built for high-heat, continuous-duty applications. Its Brushless Direct Current (BLDC) motor reduces power consumption by up to 55%, while maintaining steady airflow across the mixing area.
Unlike induction fans, which lose efficiency under voltage fluctuations, the Airzon BLDC Banbury Line Mixer Fan delivers consistent performance without speed drops or overheating. Its electronic control system ensures optimal torque, smooth operation, and minimal energy loss even during long production hours.
Key Performance Benefits:
High efficiency: Uses 80–90 watts vs. 180–200 watts in conventional fans.
Stable speed: Maintains constant airflow under variable voltage.
Reduced heat buildup: Keeps Banbury zones cooler, reducing material stress.
Low maintenance: No brushes, fewer moving parts, and extended service life.
Continuous reliability: Designed for 24/7 industrial operation with minimal downtime.
Quantifying the Savings
When implemented across a full Banbury line, Airzon BLDC Banbury Line Mixer Fans deliver measurable annual savings through lower power usage and reduced maintenance. Plants operating multiple fans can achieve tens of thousands of rupees in yearly energy cost reductions, while improving the overall temperature balance of the mixing room.
Over time, this leads to a significant cut in both operating expenses (OPEX) and carbon emissions, directly supporting the plant’s energy efficiency and sustainability goals.
Beyond Energy Process and Workplace Advantages
The benefits extend beyond reduced power consumption. The Airzon BLDC Banbury Line Mixer Fan enhances air uniformity, ensuring consistent temperature across the mixer area. This prevents localized hot spots, reduces the risk of premature rubber curing, and maintains consistent compound quality.
Its quiet and vibration-free performance also improves the workplace environment, reducing heat stress for operators and ensuring safer, more comfortable working conditions.
Additionally, lower maintenance needs mean fewer interruptions, better uptime, and improved process predictability all of which strengthen long-term productivity.
Airzon: The Smart Choice for Tyre Manufacturing Efficiency
At Airzon, every BLDC fan is designed with industrial precision and sustainability in mind. The Airzon BLDC Banbury Line Mixer Fan meets BEE and BIS efficiency standards, offering proven energy savings and reliable performance for continuous manufacturing operations.
With up to 55% lower energy consumption, longer service life, and stable operation under demanding conditions, Airzon fans redefine efficiency in tyre production facilities.
Conclusion
In tyre manufacturing, small energy improvements create major bottom-line impact. By integrating Airzon BLDC Banbury Line Mixer Fans into your energy map, you achieve more than just savings, you gain process stability, environmental compliance, and lasting operational returns.
Airzon powering sustainable performance in every revolution.
