Project Overview:
Dhanvi Infracon Pvt. Ltd. proudly partnered with Xitiz Technomech LLP, a leading name in high-performance vacuum furnace manufacturing, to build their full-scale industrial facility. The facility is designed to cater to the growing demand for technologically advanced metallurgical machinery across domestic and international markets. Dhanvi’s role spanned complete turnkey infrastructure development, from ground-breaking to commissioning, focused on enabling safe, efficient, and future-ready furnace production.
The complexity of furnace manufacturing required a highly technical setup — involving controlled atmospheric conditions, robust power infrastructure, precise foundation engineering, and intelligent space utilization. Our construction ensured that the final setup reflected the precision and innovation of the products Xitiz Technomech creates.
Key Features of the Project:
- Heavy-Duty Industrial Flooring: Reinforced RCC with epoxy finish to withstand high load and chemical exposure.
- Controlled Temperature Zones: Constructed insulated units to maintain process-specific ambient conditions.
- PEB (Pre-Engineered Building) Structure: Fast-tracked steel framework enabled quicker construction and flexibility for expansions.
- Machine-Specific Foundations: Deep-pit foundations customized to each furnace testing and assembly unit.
- Clear Height (11–12 meters): Designed for vertical movement of large components using EOT cranes.
Technologies Used in Construction:
- BIM (Building Information Modeling): For flawless integration between electrical, mechanical, and structural services.
- SCADA-Compatible Systems: Electrical and HVAC systems designed for integration with smart factory automation.
- Fire-Resistant Panels: Used in sensitive assembly areas to protect both workforce and equipment.
- Anti-Vibration Mounts: Embedded in foundations to reduce micro-movements affecting furnace calibration.
- Green Insulation Materials: For sustainable thermal regulation and soundproofing.
Construction Management and Execution Approach:
- Detailed Feasibility Study: Conducted structural analysis and ground testing before excavation.
- Material Planning & Logistics: Coordinated just-in-time deliveries due to limited on-site storage capacity.
- EHS Compliance: Enforced full Environment, Health & Safety compliance with ISO standards.
- Daily Work Reporting & Coordination: On-site engineers coordinated real-time with Xitiz Technomech’s core team.
- Phase-Wise Handover: Ensured early access to office/admin blocks while production floors were in finishing phase.
Challenges Faced:
- Precision Engineering Alignment: Furnace equipment demanded mm-level foundation accuracy; required laser leveling and 3D scans.
- Power Infrastructure Setup: Heavy voltage demand meant transformer housing, HT cabling, and switchyards needed early-stage integration.
- Ventilation & Air Purity: Manufacturing processes needed custom air handling units with HEPA and active carbon filtration.
- Noise and Vibration Control: Must protect furnace calibration units from external disturbances.
- Limited Plot Dimensions: Required intelligent design to accommodate testing labs, office spaces, warehousing, and production floors within constraints.
Advantages of the Project:
- Custom-Built for High-End Manufacturing: Facility was tailored to Xitiz Technomech’s unique production demands.
- High Energy Efficiency: LED lighting, insulated roof panels, and natural ventilation features reduce operational costs.
- Scalable Design: The layout supports future additions without major disruption.
- Premium Finish Quality: Showcases industrial aesthetics to visiting international clients.
- Faster ROI: Due to early handover and smart layout, Xitiz began furnace production weeks ahead of schedule.
Disadvantages / Limitations:
- High Initial Investment: Due to specialized infrastructure and MEP installations.
- Complex Equipment Integration: Coordination between global machinery suppliers and civil progress added layers of complexity.
- Location Constraints: Connectivity issues during monsoon seasons caused minor logistic delays.
Sustainability and Eco-Friendly Measures:
- Zero Discharge Water Treatment Plant: Captures and treats water from washing and cooling.
- Solar-Ready Roofs: Provisioned for future solar panel installations.
- Rainwater Harvesting System: Supports groundwater replenishment and reduces municipal water dependency.
- Eco-Friendly Materials: Use of VOC-free paints, recyclable steel structures, and thermally insulated panels.
Future Plans:
- R&D Centre Extension: Planned adjacent block for metallurgical research and innovation hub.
- Automation Integration: Entire facility to be upgraded for Industry 4.0 compatibility with smart sensors and analytics.
- International Assembly Line: Adding a new wing to accommodate overseas client-specific furnace builds.
- Cleanroom Facility: For precision work and prototype testing under tightly controlled conditions.
- On-Site Training Centre: A dedicated area to train operators, clients, and engineers in advanced furnace handling.
Impact on the Industry:
With this new facility, Xitiz Technomech LLP has strengthened its position as a global leader in vacuum furnace manufacturing. Dhanvi’s construction has provided the structural and functional backbone for a high-precision manufacturing unit that can now serve sectors like aerospace, defence, energy, and advanced metallurgy with top-quality equipment built entirely in India.
This construction not only enhances production capacity but also signals a leap in India’s industrial self-reliance, showcasing the synergy of construction excellence and technological manufacturing.
Conclusion:
The Xitiz Technomech LLP manufacturing unit stands as a symbol of engineering precision and future-forward infrastructure. For Dhanvi Infracon Pvt. Ltd., this project was not just another factory—it was a technical canvas that demanded absolute attention to detail, stringent quality control, and a vision aligned with global industrial benchmarks. Together, we’ve built more than a manufacturing plant—we’ve built a launchpad for innovation.
