What Goes into the Manufacturing of Super Energy Efficient BLDC Fans?

What Goes into the Manufacturing of Super Energy Efficient BLDC Fans?

From Superfan, India’s first super energy efficient ceiling fan

Traditional ceiling fans relied on energy-hungry induction motors for years, consuming around 70-80 watts of power. But a new era has dawned with the rise of BLDC technology, offering energy-efficient fans without compromising on-air delivery. BLDC fans can slash power consumption by up to 69%, thanks to their advantages over induction motors: lower electricity usage, lesser noise, and enhanced lifespan.

Ceiling fans are often overlooked when it comes to energy conservation, as attention is typically on larger appliances like air conditioners and heaters. However, India’s increasing population, its significant share of global energy demand, energy efficiency, and conservation are crucial. As a tropical country, India represents a massive fan market, with approximately 60 million units sold annually. By transitioning to brushless direct-current motor (BLDC) fans, the country has the potential to achieve substantial energy and cost savings and thereby significantly reduce its carbon footprint.

Traditional ceiling fans relied on energy-hungry induction motors for years, consuming around 70-80 watts of power. But a new era has dawned with the rise of BLDC technology, offering energy-efficient fans without compromising on-air delivery. BLDC fans can slash power consumption by up to 69%, thanks to their advantages over induction motors: lower electricity usage, lesser noise, and enhanced lifespan.

The Indian appliance industry witnessed the arrival of BLDC fans in the year 2012, but is India truly ready for this technological revolution? Let’s dive in and find out!

BLDC Motor Fans Contributing Energy Savings and Sustainability

BLDC Motor Fans offer remarkable energy efficiency, setting them apart from traditional AC Motor Fans. The energy consumption of AC Motor Fans remains high even at lower speeds. In contrast, BLDC Motor Fans are designed to operate efficiently at variable speeds, consuming significantly less energy as the speed decreases. In fact, BLDC Motor Fans can consume up to 70%  less energy than their AC counterparts. This impressive energy efficiency helps reduce overall energy consumption and contributes to a reduced carbon footprint. Given the significant contribution of 400 million fans in India to greenhouse gas emissions, adopting BLDC Motor Fans presents a valuable opportunity for households and commercial establishments to make a meaningful impact in creating a greener and more sustainable future.

India has pledged to decrease its emissions intensity by 35% by 2030 from 2005 levels. To promote energy efficiency, Energy Efficiency Services Limited (EESL) has planned the deployment of 10 million energy-efficient fans (both 3-star and 5-star rated) across India starting September 2023. The strategic initiative by EESL is in line with India’s national targets for carbon reduction, encouraging the widespread adoption of energy-efficient fans. The initiative is expected to benefit stakeholders by reducing energy consumption, lowering electricity bills, and contributing to the nation’s sustainable energy management goals. 

Moreover, BLDC motor fans have a significant advantage as they last much longer on battery backup and inverters. With their low energy consumption, they can operate up to three times longer on inverter backup, making them especially beneficial in regions

like rural areas in India where uninterrupted electricity supply is a challenge.

In addition to cost savings, BLDC motor fans offer environmental benefits by reducing electricity consumption, lowering carbon emissions, and supporting sustainability efforts. This is crucial in a country like India, with concerns over air pollution and ambitious targets for carbon emission reduction. 

BLDC V/S AC Induction Motor

A BLDC motor consists of a rotor made up of permanent magnets and a stator with windings. Unlike an AC induction motor, where the magnetic field is generated in the stator and induces a current in the rotor, in a BLDC motor, the permanent magnets generate the magnetic field in the rotor, and the stator contains the windings.

The current to a BLDC motor is a constant direct current; a varying current is required to move the motor. The electronic controller provides this varying current with a microcontroller. This controller switches the current in the stator windings on and off in a sequence. This switching sequence, or commutation, creates a rotating magnetic field in the stator that interacts with the magnetic field from the permanent magnets in the rotor. This interaction generates torque, causing the rotor to spin and drive the fan blades.

The electronic controller can precisely control the switching sequence, allowing for precise speed control. This contrasts with the slip-in AC induction motor, which makes precise speed challenging.

Furthermore, because a BLDC motor uses permanent magnets rather than inducing a current in the rotor, it generates less heat, leading to less energy wastage and a longer lifespan in principle. 

In contrast to ACIM, BLDC motors can achieve a near-unity power factor. This is because the electronic controller in a BLDC motor can adjust the current to align with the voltage, minimizing phase differences. When the current and voltage waveforms are in phase (i.e., they reach their peak values simultaneously), the power factor is 1.0, and there is no wasted power. This improves efficiency and reduces the power supply load, leading to potential cost savings for the electricity grid.

BLDC Manufacturing Process & Supply Chain

The manufacturing process of BLDC fans is markedly different from that of conventional fans with AC induction motors, both in terms of motor manufacturing and the supply chain.

Motor Manufacturing: Manufacturing a BLDC motor involves the assembly of permanent magnets on the rotor and windings on the stator. While the stator winding process is similar to AC induction motors, including permanent magnets in the rotor is a unique aspect of BLDC motor manufacturing. These magnets for

fans are typically ferrite magnets. The magnets are precisely positioned on the rotor to ensure optimal interaction with the stator’s magnetic field. This requires precision and quality to ensure the magnets are correctly aligned and securely attached.

Electronics Manufacturing: The electronic controller requires some specialized manufacturing techniques. The process involves assembling various electronic components, such as semiconductors, capacitors, and resistors, onto a printed circuit board (PCB). This assembly process can include techniques such as surface-mount technology (SMT) or through-hole technology, depending on the design of the PCB and the components used. Once assembled, the PCB would undergo rigorous testing to ensure that all components function correctly and that the board meets all electrical and safety standards.

Firmware Embedding: The firmware for the electronic controller is another critical aspect of a BLDC fan, as it controls the operation of the fan. This specifically designed firmware must be embedded into the controller during manufacturing. The process of embedding the firmware is programming the microcontroller. Once the firmware is embedded, it is tested to ensure that it operates correctly and provides the desired operation.

Supply Chain: The supply chain for BLDC fans differs from traditional fans in a few ways and is mainly the extra components, magnets, and electronics. The permanent magnets used in the rotor need to be sourced from specialized suppliers that can give it in the form that fits the fans. Similarly, the electronic components for the controller require a supply chain that can provide high-quality semiconductors, capacitors, and other electronic parts.


The fan industry in India commands a sizable market and is the leading product in the brown goods category. Fan sales exhibit consistent performance across regions, with no significant disparities. Notably, India’s fan industry has witnessed substantial export growth in recent years, showcasing the industry’s standards and progress within the country.

This progress also aligns with India’s pursuit of net-zero carbon emissions by 2070, supported by several astute initiatives. These include the installation of non-fossil fuel sources to generate 50% of power by 2030, the Hydrogen Energy Mission, and the Perform Achieve and Trade (PAT) scheme of the Bureau of Energy Efficiency (BEE) for energy savings. In line with these efforts, promoting the adoption of energy-efficient BLDC fans will contribute significantly to realizing the ambitious emission reduction targets. Seizing such low-hanging fruit is crucial in a journey toward sustainability.

In the era of evolving consumer preferences, government policies promoting sustainability, and a growing awareness of eco-friendly lifestyles, adopting BLDC (Brushless DC) fans is poised for remarkable growth. Consumers ‘ interaction with fans has transformed with changing work dynamics like WFH (Work from Home) and hybrid cultures. They seek premium, energy-saving options that align with their eco-conscious choices. The revolutionary impact of BLDC fans is set to reshape the fan industry, introducing a wave of highly efficient, environmentally friendly solutions. Get ready to embrace the future of sustainable living with these transformative fans.

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