How AERSTER Air Curtains Saved 40% Energy at a Pune Warehouse

A Pune logistics warehouse cut its cooling-related energy costs by around 40% after installing AERSTER industrial air curtains and PVC strip curtains at its dock doors and main entrance. The combination kept conditioned air in and hot outside air, dust, and insects out — without slowing forklift and personnel movement through the openings.

The challenge

The 80,000 sq ft warehouse ran multiple dock doors that stayed open for long stretches during loading and unloading. Pune's summer heat poured in through these openings, the cooling system struggled to keep temperature stable, and dust from the yard settled on stored goods. Closing the doors was not an option because it would stall the loading operation.

The solution

AERSTER recommended a layered barrier approach at each opening:

Industrial air curtains at the main entrance and personnel doors

High-velocity SS304 air curtains created a continuous air barrier that let people walk through freely while blocking heat and flying insects.

PVC strip curtains at the dock doors

Heavy-duty PVC strip curtains at the high-traffic loading docks held back heat and dust while still allowing forklifts and pallets to pass straight through. The strips self-close after each pass, so there is no manual operation.

The results

After installation the facility reported roughly a 40% reduction in cooling-related energy costs, more stable internal temperatures across shifts, noticeably less dust on stored inventory, and fewer flying insects inside — all while maintaining full loading throughput. The payback on the equipment came well within the first operating season.

Why the combination works

Air curtains and PVC strip curtains solve the same problem in different ways. Strip curtains are ideal where vehicles and pallets pass through, because the physical strips form a tight seal. Air curtains are ideal where people walk through, because there is no physical contact. Using each where it fits best gives the strongest overall barrier for a large facility.

Frequently asked questions

How much can a warehouse really save with air curtains?

Savings depend on climate, door size, and how long openings stay open, but facilities with frequent or continuous door traffic commonly see substantial cuts in cooling load. This Pune site reported about 40%.

Should I use air curtains or PVC strip curtains for a dock door?

For dock doors with forklift and pallet traffic, PVC strip curtains usually give the tightest seal. Air curtains are better for personnel entrances. Many large warehouses use both.

Will strip curtains slow down loading?

No. Strips part as a forklift or pallet passes and fall back into place automatically, so loading continues without manual handling of the barrier.

Does AERSTER help with sizing for large facilities?

Yes. AERSTER sells factory-direct and can recommend the right air curtain and PVC strip curtain specification for each opening, with bulk pricing and GST invoicing.