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Built-to-Suit Manufacturing Facility for RENK India in Shoolagiri

Overview

RENK had been operating a manufacturing facility in Bangalore’s Bommasandra Industrial Area. To advance its growth strategy and enhance production capacity in India, RENK embarked on a project to establish a new, state-of-the-art manufacturing facility within a prominent industrial cluster. This expansion aimed to strengthen RENK’s logistical efficiency and proximity to its customer base, enabling improved responsiveness to market demands.

To achieve these goals, RENK was looking to partner with a Grade A developer with a proven track record in delivering advanced industrial and warehousing facilities. This collaboration was central to ensuring that the new facility met stringent standards of operational excellence, sustainability, and innovation, reinforcing RENK’s commitment to compliance, quality and customer satisfaction.

RENK selected Horizon Industrial Parks due to its proven expertise as an institutional developer with a track record in building and managing high-quality industrial parks. Horizon’s commitment to meeting rigorous standards in effective design and sustainability aligns with RENK’s needs for a reliable, compliant, and efficient environment.

Sector:

Propulsion and Drivetrain Solutions

Company Overview:

The RENK Group is a global leader in high-efficiency propulsion and drivetrain technology, creating systems that apply substantial force to power vehicles, vessels, and machinery effectively. RENK delivers engineered solutions for clients across the defence, energy, and industrial sectors worldwide.

Founded in 1873 by Johann Julius Renk in Augsburg, Germany, the company has a remarkable 150-year legacy of success. Headquartered in Augsburg, RENK Group operates eleven manufacturing facilities across Germany, the USA, Switzerland, the UK, France, and India, all part of a global network spanning 19 locations dedicated to manufacturing, technical support, and maintenance. RENK currently employs over 3,700 people worldwide and achieved revenues of EUR 926 million in 2023.

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Renk’s New Manufacturing Facility: A Closer Look

This bespoke facility for RENK India spanning nearly 83,000 SFT has been meticulously designed to optimise efficiency, creating a campus-like environment that integrates manufacturing, assembly, and storage areas within one cohesive space. The facility is divided into two main areas: an administrative area and a shopfloor area. The shopfloor area includes the production and warehouse zones. The production area is organised into three separate bays, each dedicated to specific processes: the VMS Bay for assembling defence gearboxes, the VRM Bay for assembling industrial gearboxes, and the Machining Bay for manufacturing spare parts. Other specific requirements include:

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Crane support for loads ranging from 5 to 60 tonnes, ensuring seamless handling of various equipment sizes and weights.

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The “Campus in Factory” approach, integrating essential functions within a single, cohesive area to improve communication and operational flow between departments.

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Specialised marine chambers to accommodate unique product requirements.

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Plug-and-play stations that provide flexibility for production lines and simplified set-up.

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Full-height partition for secure handling of classified defence products, maintaining confidentiality.

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Reserved space for future expansion to accommodate scaling-up and evolving business needs.

HORIZON INDUSTRIAL PARKS’ SOLUTION: THE KEY HIGHLIGHTS

Strategic and Well-Connected Location
RENK’s new manufacturing facility is strategically situated in Horizon Industrial Park Hosur, near Shoolagiri in Tamil Nadu. Located along National Highway 44, the park offers excellent connectivity to Bengaluru City and its International Airport, as well as key transport routes, including NH 44 and the forthcoming Satellite Town Ring Road (STRR). The STRR, a six-lane road, will link twelve satellite towns around Bengaluru, further improving access to NH 844 (Hosur – Dharmapuri).
The facility is located near the well-established SIPCOT industrial cluster, comprising Phases 1, 2, and 3, which host numerous well-known manufacturing companies. Furthermore, it is strategically positioned close to major automotive players such as Ashok Leyland, Titan, Tata Electronics, Delta, Ola Electric, Ather Energy, TVS Motors, and Simple Energy, making it an ideal location for collaboration and growth within the automotive sector.

Adherence to the Stipulated Timeframe
Horizon is on track to complete and deliver the built-to-suit facility according to the agreed timeline. The dry access will be ready at the 7-month mark, with the final handover scheduled at the 9-month mark, ensuring that all milestones are met as planned.

Compliance with Local Regulations
RENK India specifically chose Horizon Industrial Parks for its demonstrated commitment to compliance by adhering to local, state, and national regulations for each of their projects. The RENK facility in Horizon Industrial Park Hosur meets the highest design, sustainability, and operational standards, and it also carefully navigates and fulfils all statutory and standard approvals necessary for manufacturing and storage.

Efficient Design and Layout
Each feature of the RENK facility demonstrates a high level of efficiency and adaptability, supporting seamless, independent operations and ensuring the facility is resilient, scalable, and aligned with complex operational demands. These include:

  • Separate entry and exit gates provide smooth access to the main spine road of the logistics park, ensuring seamless traffic flow.
  • Dedicated parking close to office and worker entrances also minimises movement inefficiencies.
  • The facility includes purpose-specific bays in the production building with multiple partitions.
  • Attention to detail towards the careful layout design of the section of the building, that would deal with the national defence department related gear box production.
  • Structural elements support cranes with capacities ranging from 5 to 60 tonnes, enhancing the facility’s ability to handle heavy machinery efficiently.
  • Reinforced flooring in specific bays withstands loads up to 10 MT/sqm, making the space ideal for managing heavy equipment.
  • The facility includes floor pits, drainage, and enclosures tailored for specific testing functions.
  • A dedicated utility area and infrastructure for installing equipment, like an Effluent Treatment Plant (ETP) for the paint booth, streamline operational processes.
  • A fully furnished G+1 office block attached to the main plant includes about 50 workstations, a 72-seat canteen, washrooms, and meeting spaces, offering convenience and cohesion for administrative functions.
  • To prevent any disruption from heavy crane movements, structural design isolates the office block from potential vibrations, ensuring a stable workspace environment.

ESG-Compliant Manufacturing Unit
Horizon’s approach to ESG compliance in its facility design emphasises energy efficiency, water conservation, and reduced reliance on non-renewable resources:

  • The facility is designed with space and structural provisions to accommodate future rooftop solar installations, aiming to harness renewable energy to reduce carbon footprint.
  • Rooftop skylights maximise the use of natural daylight, which lowers daytime electricity consumption.
  • Natural ventilation through louvers and roof monitors facilitates 4-6 air changes per hour throughout the facility, decreasing the need for artificial cooling and improving indoor air quality.
  • The facility includes a dual plumbing system that separates water lines for flushing and domestic use. It also uses recycled, treated water for toilets, reducing freshwater demand.

LED lighting fixtures throughout the facility meet optimised lux levels for general lighting while minimising energy consumption. The HVAC systems in the office areas are also designed for high energy efficiency.

On a final Note

Working with RENK India has further expanded our understanding of managing complex, specialised industrial real estate projects with plenty of valuable insights. We found that engaging with clients during design workshops is crucial to achieve optimal end-product benefits, especially for projects in niche industrial segments. Work scope management and change management during the design phase demands extra effort and attention, particularly when working with cost-sensitive clients, which we were mindful of. The practice of consistent reviews between clients and Horizon’s projects and leasing teams enables early resolution of design conflicts and ensures the project is staying on schedule. Ultimately, at Horizon, we believe that effective stakeholder management is paramount to the successful development of built-to-suit (BTS) industrial projects, and hence, we prioritise collaboration, transparent communication, and proactive problem-solving at every stage.

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