As the pace of technological innovation increases and human beings have to process more information and perform increasingly complex tasks, it becomes increasingly important for architectural design to respond to these needs. Employee well-being is at the core of A.T.E.’s values and has sustained our businesses for nearly eighty years. This presentation discusses various considerations that influence employee well-being in factories and how this can be improved, resulting in higher employee satisfaction and productivity.

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Presented at CII-IGBC Conference on Green Factory Buildings, Chennai, 22 December 2017
Occupants’ Well-being in Factory Buildings
Dr. Prasanna Rao Dontula
Chief Technology Officer & Head — Energy Efficiency Solutions
A.T.E. Enterprises Private Limited
A.T.E. Enterprises Private Limited
V2.0 May 2017

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A.T.E. At A Glance
BUSINESSAREAS
Textile Engineering
Cooling
Wastewater Treatment
Flow Technology
Energy Efficiency
Internet of Things for Industry
Print & Packaging
Value Enhancing Systems
OURTECHNOLOGIES
Textile Spinning
Industrial Internet of Things
Heat Exchange
Wastewater Management
Static and Ink Control
Print Control and Vision Systems
5000+ happy customers 500+ world-class products 14 locations
75+ years experience

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 Comfort
Conditioning
Systems
 Heat
Management
Systems
 Humidification
and Filtration
Systems
 Solar Thermal
 Energy Audits
 Retrofits &
Accessories
A.T.E.’s Portfolio For “Green Factories”
AIR
WATER
 Effluent Treatment
Plants
 Sludge treatment
ENERGY
Remote Monitoring Systems and Industrial Internet of Things (IIoT)

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Does going “Green” have an
economic benefit?

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The Heath of Munition Workers’ Committee (HMWC) was set up in 1915 by Ministry of Munitions & Home Secretary to advise
on questions of industrial fatigue, hours of labour, and other factors affecting health and physical efficiency of workers in
munition factories and workshops.
Their first 15 recommendations
A Quick Look Back In Time ……
Sunday labour Effect of industrial conditions on eye-sight
Hours of work Welfare supervision
Output in relation to hours of work Canteens and their construction
Industrial fatigue and causes Workers food and considerations to dietary
Sickness and injury Washing facilities and bath
Special industrial diseases Employment of women
Ventilation and lighting Employment of juveniles

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Community
Health Psychology
Our Motivation To Foster Well-Being
PERFORMANCE /
PRODUCTIVITY
“Building design is a critical tool in the promotion of societal health and well-being, yet there remains a
radical disconnect between the physical expectations placed on workers and the architectural response to
such demands.”
Mr. Anuj Bhagwati, Managing Director, A.T.E.

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HMWC (1915-1917) observed:
• Working in insufficiently ventilated workshops predisposes to disease and gravely interferes with individual
energy and physical capacity …. Continuously working in a stagnant atmosphere is not trivial
• The air, even if fresh, may be too hot or too cold, too humid or too dry; either extreme should be avoided to
ensure reasonable bodily comfort and the most efficient work
• Some contemporary studies on comfort and productivity:
• 12% higher productivity possible by maintaining comfort conditions Sharma & Chandwani 2016 IIM Ahmedabad study
on Indian factories
• 0.2% rise in productivity for each 1°C fall in temperature in the range 28-33°C Adhvaryu et al. 2014 U Michigan on
29 export-oriented garment factories in Bangalore, 215,000 line-day observations over 941 days
Health

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Health: Comfort
“That condition of mind which expresses
satisfaction with the thermal environment
and is assessed
by subjective evaluation.”
ASHRAE Standard 55
Thermal Environmental Conditions for Human Occupancy

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Comfort
Human body produces 100-150 W of heat under normal conditions and
moderate activity level
This heat must be “dissipated” in order to maintain
constant body temperature
Heat in Heat out
When human body attains constant temperature, it is said to be “comfortable”

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Human body can lose heat (“dissipation”) by various mechanisms
• Conduction to air due to difference between temperature of air in contact with that of the human body
• Convection to air due to temperature difference and air movement
• Radiation to surrounding walls due to difference in temperature of surfaces not in contact
• Evaporation driven by moisture levels in air
Comfort In Engineering Terms

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Adaptive Model of Comfort
ASHRAE limits valid for :
• Operable windows
• No mechanical cooling
• Metabolic rate 1-1.3 met
• Clothing Level 0.5-0.7 clo
ASHRAE Software Tool for Comfort
http://smap.cbe.berkeley.edu/comforttool
IndoorOperativeTemperature,°C
f(IndoorTemperature,MRT)
Prevailing Mean Outdoor Temperature
(Moving average of mean daily temperature, 7-30 days,
single value for each day of year)
10 °C 33.5 °C
31.7°C
24.7°C
2
1
ASHRAE 55-201, Section 5.3

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Adaptive Comfort Is Applicable in India
ASHRAE limits
• Operable windows
• No mechanical cooling
• Metabolic rate 1-1.3 met
• Clothing Level 0.5-0.7 clo

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Evaporative Cooling Delivers Comfort under Indian Conditions
Direct Evaporative Cooling (DEC)
Indirect Evaporative Cooling (IEC)

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Case 1: World’s Largest Automobile Manufacturer
Location Pune, India
Project
Body shop, assembly area, paint shop, engine shop, solvent
store and R&D center
Total area cooled 350,000 ft2
Supply air 2,300,000 cfm (multiple capacities)
Customer requirements Discomfort due to heat inside the factory sheds
Other solution suggested Ventilation units
Solution provided by A.T.E. Indirect Direct Evaporative Cooling
Reasons for selection
Greater comfort compared to ventilation. No moisture
addition to supply air as in direct evaporative cooling
Annual power consumption 6,624,000 kWh
Annual water consumption 88,320,000 litres
Year of commissioning 2010 ̶ 2016

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Case 2: India’s Largest Flexible Packaging Company
Location Noida, India
Project Flexible printing area
Total area cooled 100,000 ft2
Supply air 420,000 cfm (35 k x 12)
Customer requirements Poor indoor air quality due to VOC
Other solution suggested Screw-type water cooled chiller of 800 TR
Solution provided by A.T.E. Indirect Direct Evaporative Cooling
Reasons for selection
100% fresh air with positive pressure reduces dust ingress
and improves printing quality. 70% lower power
consumption than AC.
Annual power consumption 1,411,200 kWh
Annual water consumption 16,128,000 litres
Year of commissioning 2015

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Case 3: World’s Largest Automotive OEM
Location Oragadam near Chennai, India
Project
Manufacturing, assembly area, testing area of electrical
drives unit
Total area cooled 45,500 ft2
Supply air 178,000 cfm
Customer requirements Discomfort due to heat inside the factory sheds
Other solution suggested Ventilation units
Solution provided by HMX Indirect Direct Evaporative Cooling
Reasons for selection
Improved cooling and suitability to factory-shed cooling
along with energy savings

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Fresh Air
HMWC (1915-1917) observed:
• Efficient ventilation is absolutely essential for the maintenance of health and comfort, and therefore efficiency
and capacity of the workers
• Some contemporary studies on fresh air and productivity:
• US soldiers got more coughs and colds if they slept in air-conditioned barracks than if they slept in tents and
warehouses Richards et al 1993a on 2598 soldiers stationed in Saudi Arabian desert during Gulf War I
• 8.8% higher operator performance at a call centre by raising fresh air supply from 9.8 to 22.7 l/s-person (at
indoor temperature 24.5°C) Tham et al. 2003 call centre in Thailand
• Common colds in crowded dormitories fell by 85% by raising fresh air to 5 l/s-person from 1 l/s-person
Sun et al. 2011 3700 students in 1500+ dorm rooms
• CO2 in the ambient can be regarded as a pollutant rather than an indicator of low supply rate of fresh air
Satish U. et al. 2012

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Open office
100% fresh air cooling
Sky-lights
Energy efficient features
A.T.E. EcoAxis factory and office, Pune
LEED Gold rated facility
2015

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(Day)-Lighting
HMWC (1915-1917) observed:
• Bad lighting affects output unfavourably, not only by making good and rapid work more difficult but by causing
headaches and other effects of eyestrain
• Use of day-lighting reduces energy consumption
• Some contemporary studies on day-lighting and productivity:
• In retail, the presence of skylights was the most-important criterion and statistically significant architectural
factor to increase sales volume Heschong Mahone Group 1999 & 2002 Day-lighting and human performance
• Surgery patients in rooms that had windows facing trees recovered 8.5% faster and took fewer pain-killers
analgesics than those patients whose view was a brick wall Ulrich 1984 Day-lighting and patient recovery
• Sunlight coupled with fresh air reduces spread of airborne TB infection in hospitals in Peru Swain 2013

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Transparent
polycarbonate roof
Polished aluminium layer
under the polycarbonate
roof reflects 98% of the
sunlight
Polished aluminium inner
surface radiates less heat
into the factory
100% fresh air cooling
Day-lighting significantly
reduced energy for
lighting
A.T.E. TeraSpin factory, Sari, Ahmedabad
LEED Gold rated facility
2014

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“Having worked in air-conditioned offices for
several years, I have experienced slight headaches
towards the end of the day around 4 pm. This does
not happen in the TeraSpin premises….. breathing
fresh air all day and being in natural light all
through the working hours”
A.T.E. TeraSpin factory, Sari, Ahmedabad
LEED Gold rated facility
EPI of office building: 78 kWh / m2-year
2014

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Canteens and Rest Spaces
HMWC (1915-1917) observed:
• The Committee expresses the opinion that by far the most hopeful enterprise has been the establishment of
industrial canteens or workpeople's dining rooms in or near the factory
• It was not merely a question of supplying food, but of doing so under restful and comfortable conditions, in
rooms well-lighted, ventilated and properly warmed
A.T.E. EcoAxis factory, Pune
LEED Gold rated facility
EPI of office building: 124 kWh / m2-year
2015

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• As the pace of technological innovation intensifies and human beings are asked to process more
information and perform increasingly complex tasks, it becomes increasingly important for
architectural design to respond to these needs
• A thoughtfully designed space can increase productivity, foster a sense of community, and
reduce environmental impact
Parting thoughts

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“The open arrangement created an entirely new culture — a culture beyond functions, divisions
and technologies”
A.T.E. EcoAxis factory and office, Pune
LEED Gold rated facility
2015

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THANK YOU