Balaji Wafers Pvt Ltd |Enhancing FMCG's Production Efficiency with HIMALAYA's Cooling Solutions

Case Study: Enhancing Production Efficiency at Balaji Wafers with HIMALAYA Cooling Solutions

Client:
Balaji Wafers Pvt. Ltd.
One of India’s leading manufacturers of wafers, fryums, and namkeens.

Industry:
Food Processing & FMCG

Location:
Manufacturing Facility – Gujarat, India

Background

Balaji Wafers is a household name across India, known for its wide range of snacks including potato wafers, fryums, and namkeens. With a state-of-the-art production facility and high-speed processing lines, temperature and humidity control were critical to ensuring product quality, shelf life, and hygienic conditions.

Due to the nature of their product lines and continuous production cycles, heat generated from machinery, ovens, and packed equipment often led to elevated ambient temperatures on the shop floor. This posed a challenge for:

• Maintaining crispness in wafers and fryums

• Preventing spoilage in spices and namkeens

• Ensuring optimal operation of packaging and electronics equipment

Challenges

• High ambient temperature in production and packaging areas

• Heat load from processing lines affecting product quality

• Moisture control in seasoning and packaging zones

• Frequent overheating of control panels and PLC cabinets

Our Solution

HIMALAYA Refrigeration Industries partnered with Balaji Wafers to provide a complete industrial cooling solution to stabilize temperature and ensure smooth operations:

✅ Panel Air Conditioners:
Installed on electrical panels, PLC cabinets, and automation units to prevent overheating and ensure uninterrupted control system performance.

✅ Variable Speed Water Chillers:
Supplied energy-efficient, variable speed chillers that adapt to real-time cooling demand, supporting heat-sensitive equipment and maintaining ideal conditions in seasoning and packaging zones.

Supplied Equipment

• Panel Air Conditioners:

  • Capacity: 500W to 8500W

  • IP Rated for dusty and oily environments

  • R134a eco-friendly refrigerant

  • Maintenance-free operation with inbuilt temperature control

• Variable Speed Water Chillers:

  • Adaptive cooling based on load fluctuations

  • Integrated tank and pump system

  • Temperature range: 10°C–25°C

  • Food-grade construction

  • Energy-saving inverter-based scroll compressors

Results & Benefits

📈 Improved Equipment Uptime:
Zero downtime of control panels due to overheating.

🌡️ Consistent Product Quality:
Maintained ideal temperature during seasoning and packaging processes.

💨 Enhanced Working Conditions:
Lower ambient heat in operational zones increased worker comfort and productivity.

⚙️ Energy-Efficient Operations:
Variable speed chillers reduced energy consumption by adjusting output to real-time load.

Client Feedback

“HIMALAYA’s cooling systems helped us stabilize production and maintain consistent product quality even in peak summers. Their after-sales support is prompt and reliable.”
— Keyurbhai Virani, Balaji Wafers Pvt. Ltd.

Conclusion

With HIMALAYA’s tailored cooling solutions, including panel air conditioners and variable speed water chillers, Balaji Wafers achieved superior climate control across critical manufacturing zones—ensuring product integrity, energy efficiency, and operational reliability.