Manufacturing Excellence
Delivering unwavering quality and unmatched performance.
Our Manufacturing
Blue Star takes pride in its commitment to excellence, which is reflected in its comprehensive 'Manufacturing Excellence Programme'. This programme fosters world-class quality and efficient production practices and invests heavily in employee skill development. It all starts at the manufacturing plants, where our 'Customer-First' philosophy comes to life. Every team member, process, and division is dedicated to crafting exceptional products that meet and exceed customer expectations. | Our Four Main Pillars for Manufacturing Excellence
Blue Star's factories boast state-of-the-art equipment, including high-end computer numeric control (CNC) machines such as fibre laser-cutting machines and automatic panel benders from Salvagnini, Italy; turret punching machines from Amada, Japan; and powder coating machines with iControl features from Nordson, USA, among others. |
Technology
Innovative Manufacturing
High-tech coil manufacturing with equipment from Burr Oak Tool ensures high-efficiency coils. Auto brazing machines from S K Brazing, Korea, enhance the brazing process. Shell and tube heat exchangers are precision-manufactured in-house.
Micro Channel Heat Exchangers
At Blue Star, we excel with our in-house micro channel heat exchanger manufacturing line, producing condenser coils and fin core builders. Components are assembled on automated conveyor lines, facilitating mass production and component traceability.
VRF Manufacturing
Our unique assembly line for VRF includes an auto oil charging machine and state-of-the-art test cabins for 100% testing, meeting international standards.
Today's Legacy
We embrace IT tools to boost productivity, quality, and waste reduction. A dedicated quality portal empowers engineers with real-time data for trend monitoring and corrective actions.
IT Tools for Efficiency
By leveraging IT tools, we boost productivity, quality, and waste reduction. Our dedicated quality portal empowers engineers with real-time data for trend monitoring and corrective actions.
Eco-Friendly Focus
Blue Star ensures eco-friendliness and compliance with updated regulations. For instance, polyurethane foam panels use cutting-edge eco-friendly technology with zero ozone depletion and lower global warming potential.
Manufacturing Facilities
Blue Star has extensive product testing facilities, which enable the development and manufacturing of high-quality products at our various factories in India.
Sri City, India
Blue Star's AC manufacturing plant in Sri City near the Chennai Port, India, primarily caters to the South and West market requirements. Its strategic positioning ensures the efficient transportation of products. Additionally, it is positioned to serve overseas demand in Europe and North America through the International Business Group in the future. This state-of-the-art facility boasts cutting-edge machinery with the latest automation techniques and tools, facilitating top-tier manufacturing processes. With a remarkable capacity of 322,000 units in the fiscal year 2024, it aims to scale up to an impressive 1.6 million units within the next five years. The facility also emphasises increased value addition through backward integration while leveraging benefits such as Production Linked Incentives (PLI), income tax benefits, and Manufacturing and Other Operations in Warehouse Regulations (MOOWR) benefits, further enhancing its competitive edge in the global market.
Dadra, India
Blue Star's AC manufacturing plant in Dadra has been built in technical collaboration with Rheem, USA, and exemplifies cutting-edge manufacturing. Recognised as a leading Indian air conditioning hub, it leverages an integrated SAP ERP system for seamless operations. It implements advanced principles like visual factory management, Just-in-Time, Kaizen, and Lean methodologies for ensuring efficient production and minimising errors. Its highly integrated assembly line boasts strong backward integration with coil shops, fabrication shop, paint shops and powder coating shop, enabling the production of a diverse portfolio including ducted & ducted inverter units, inverter VRF ACs, and more. This facility showcases Blue Star's commitment to innovation and efficiency in air conditioning manufacturing.
Himachal Pradesh Plant 1, India
The industrial zone of Kala Amb in the Solan district of Himachal Pradesh, India, has seen a proliferation of manufacturing setups in the recent past. Our AC manufacturing plant has successfully capitalised on this opportunity to augment its manufacturing capabilities. This factory has been set up in the sylvan settings of Kala Amb, India. It is a highly productive, automated, and flexible unit that manufactures outdoor and indoor units of split air conditioners coupled with a fin and tube heat exchangers (FTHX) coil manufacturing setup with backward integration equipped with world-class sets of equipment like Burroak USA and Hidaka Japan, among others. The plant is equipped to manufacture inverters and fixed-speed ACs, along with smart AI features and heating & cooling units to cater to North India’s extreme climate. The overall manufacturing capacity is 5,00,000 AC units.
Himachal Pradesh Plant 2, India
This state-of-the-art manufacturing plant is equipped with highly productive, automated, and flexible lines that manufacture outdoor and indoor units of split air conditioners. Coupled with a fin and tube heat exchangers (FTHX) coil manufacturing setup with backward integration, the ACs are built with world-class equipment from Burroak USA and Hidaka Japan, among others. This facility also manufactures commercial split ACs, including Cassette, Mega Split and Verticool units and has a manufacturing capacity of 300,000 AC units.
Wada, India
The strategic location of this Blue Star air conditioning manufacturing facility in Wada near Mumbai, India, positions it to become the largest manufacturing hub. This modern plant deploys cutting-edge systems for quality and efficiency, utilising Lean Manufacturing, Six Sigma, and Kaizen methodologies. Notably, the facility achieved a Platinum-rated IGBC Green Building certification in 2022, underscoring its commitment to sustainable practices. These initiatives include maximising natural light and ventilation, using energy-efficient cooling systems, water conservation measures, and eco-friendly landscaping. Furthermore, as a part of our renewable energy adoption, this facility has added a 2.1 MW Roof Top Solar Plant in April 2023 to the existing 1 MW Plant, augmenting it to a 3.1 MW Roof Top Solar Plant. This recognition highlights Blue Star's dedication to responsible manufacturing and environmental leadership.
Ahmedabad, India
Located in Changodar on the Ahmedabad-Rajkot Highway in India, this cutting-edge manufacturing plant produces deep freezers with a high level of automation on the assembly line, sheet metal fabrication line, and foaming setup.
With computerised control ambient Performance testing to ensure first time right product. Plant producing products as per BIS Licence for IS 7872 & BEE marking. Certified for ISO 9001, ISO 14001 & ISO45001.
Quality
We are committed to building exceptional products. Our rigorous Quality Assurance (QA) and Quality Control (QC) processes, from testing raw materials to pre-dispatch inspections, ensure every product delivers lasting performance and reliability. | Blue Star ensures quality from the very beginning by testing all incoming materials to meet strict standards. Throughout the manufacturing process, we conduct meticulous quality assessments at each stage, guaranteeing consistent excellence. Before any product leaves the factory, it undergoes a final comprehensive inspection, guaranteeing it meets all performance and reliability criteria. |
 AHRI-Certified Chiller Testing Lab
Blue Star's AHRI-certified chiller testing sets the standard for performance and reliability, ensuring every chiller delivers as expected. |  Comprehensive Reliability Testing
Blue Star goes beyond functionality with rigorous testing for durability. Products endure trials for electrical safety, longevity, and environmental resilience, ensuring they perform flawlessly in diverse real-world conditions. |  External Verification
Partnering with external standards agencies strengthens Blue Star's commitment to rigorous quality assurance beyond internal testing. |
