These films take you inside SYS Electromac’s fan plant at IDA Bollaram, Hyderabad — from incoming inspection of raw materials to finished fans moving into the warehouse — and through the two sister units that mould our plastic parts and make our fan guards.
When these were filmed. The company film was shot in October 2022; the three shorter walk-throughs below it date from May 2020. The plant has been upgraded continuously since, so some machines, layouts and line equipment you see here have since been replaced or added to. The process, and the testing at every stage, is the same. For current photographs of each process, see the gallery.
The plant at a glance
| Capacity | 150,000 fans a month (1.8 million a year) |
| Plant | 100,000 sq. ft. — 60,000 manufacturing, 25,000 warehousing, 15,000 ancillary |
| Lines | 3 conveyorized assembly lines with built-in STR test cabins |
| Testing | 100% of motors and 100% of finished fans |
| Warehouse | In-line storage for 30,000 finished fans |
| Inspection | 4 pre-dispatch inspection cabins for customers |
Company film (2022)
SYS Electromac company film, October 2022. 6 min 30 s.
The film follows a fan through the plant in the order it is built. Jump to a section:
- 1:21 Incoming quality control — winding wire checked on a micrometer and for elongation, rotors and shafts checked against drawing, and packaging cartons burst-tested before anything reaches a line.
- 2:13 Machine shop — special purpose machines drill and tap motor covers in a single cycle; bushes and shafts are pressed and rotors checked.
- 3:11 Winding — automatic coil winding in copper or aluminium, then coil insertion, forming, lacing and varnishing.
- 4:01 Motor assembly — on a conveyorized line, with 100% of motors tested in STR cabins before they move on.
- 4:48 Finished-product assembly — every fan tested in built-in STR cabins, then packed on-line to the brand’s specification.
- 5:23 Handling and warehouse — conveyorized movement to a warehouse that holds 30,000 finished fans.
- 5:33 Inspection — self-inspection against agreed lot sizes, and four pre-dispatch inspection cabins for customers’ own inspectors.
- 6:18 Sister units — in-house injection moulding and fan-guard manufacturing.
Earlier walk-throughs (2020)
Three shorter films from May 2020: the fan plant, and the two sister units that make it possible to colour-match every component of a fan from one location — plastic parts moulded on 12 injection moulding machines from 80T to 220T, and fan guards made in-house at 100,000 sets a month.
Fan plant walk-through, May 2020.
Injection moulding unit, May 2020.
Guard factory walk-through, May 2020.
Visit the plant
Buyers are welcome at the plant, and most long-term relationships start with a visit. We are at 131 S.V. Co-operative Industrial Estate, IDA Bollaram, Hyderabad 502325, open Wednesday to Monday (closed Tuesday). Arrange a visit, or a live video walk-through of the current line, on WhatsApp or by phone on +91 9177 068 845.
Related: infrastructure · quality and testing · certifications · exports
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