How an Electronics Manufacturer Reduced MAU Energy Consumption by Up to 36% with an EC Fan Wall Retrofit-Project Case Studies

In electronics manufacturing, Make-Up Air Units (MAUs) often operate around the clock to maintain stable indoor air quality and production environments.

While many facilities continue to rely on traditional belt-driven fan systems, rising energy costs and increasing maintenance requirements are prompting manufacturers to rethink their HVAC strategy.

Recently, Beijing Hengrui completed a feasibility study for an EC fan wall retrofit on two MAU systems in an electronics manufacturing facility.

The objective was straightforward:

Maintain the required airflow while reducing energy consumption and simplifying long-term maintenance.

The Challenge

The existing MAUs were equipped with conventional belt-driven centrifugal fans powered by AC motors.

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Pic.1 Equipment nameplate before renovation

Although the systems were operating normally, they presented several common challenges:

· High energy consumption

· Belt wear and regular maintenance

· Mechanical transmission losses

· Limited airflow control

· Reduced efficiency over long-term operation

For facilities running 24/7, these issues translate into higher operating costs year after year.

The Retrofit Solution

Instead of replacing the entire MAU, the proposed upgrade focused on replacing the original fan assemblies with high-efficiency EC fan wall systems.

The retrofit maintained the original airflow requirements while introducing multiple EC backward-curved centrifugal fans.

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Pic.2 Comparison before and after renovation

Compared with traditional belt-driven systems, EC fan walls offer:

· Higher operating efficiency

· Direct-drive design without belts

· Easier maintenance

· Improved airflow uniformity

· Precise speed control

Performance Results

The engineering evaluation showed significant energy-saving potential while maintaining the original airflow requirements.

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Pic.3 Estimated savings (based on continuous 24/7 operation and local electricity pricing）.

Beyond Energy Savings

The benefits of EC fan wall retrofits extend well beyond lower electricity consumption.

The upgrade also helps improve:

· ✔ Airflow stability

· ✔ System reliability

· ✔ Maintenance accessibility

· ✔ Reduced mechanical wear

· ✔ Lower lifecycle operating costs

Because the fan wall uses multiple EC fans instead of a single belt-driven assembly, the system also provides greater operational flexibility and easier servicing.

Why More Manufacturers Are Upgrading MAUs

For many industrial facilities, HVAC systems are no longer viewed as supporting equipment.

They have become an important part of overall operational efficiency.

As electricity prices continue to rise and manufacturers pursue smarter, lower-maintenance facilities, upgrading existing MAUs with EC fan wall technology offers a practical way to improve performance without replacing the entire air handling system.

Let's Discuss

Are your MAU or AHU systems still relying on traditional belt-driven fans?

Have you evaluated how much energy and maintenance cost an EC fan wall retrofit could save over the equipment's lifecycle?

At Beijing Hengrui, we work with electronics manufacturers, HVAC OEMs, cleanroom contractors, and industrial facility operators to optimize airflow performance through EC fan retrofit solutions. If you're considering an MAU or AHU upgrade, we'd be happy to exchange practical engineering insights from real-world retrofit projects.