Overview
Pi Green Innovations is on a bold mission: to make the air cleaner by reducing particulate emissions from diesel generators and other industrial sources.
Their flagship product, the Carbon Cutter, is a patented retrofit emission control device designed to reduce air pollution without the need for filters or frequent maintenance. But even groundbreaking ideas can hit operational roadblocks. As demand grew for its flagship product, Pi Green faced mounting pressure to scale up production without compromising on quality or efficiency.
That’s where Karkhana stepped in.
Project at a Glance
- Industry
Environmental Services
- Product
Drum Assembly of Carbon Cutter for Gensets
- Services Offered
Complete sourcing and project management to ensure seamless manufacturing and scale-up production.
- Capabilities Leveraged
End-to-end fabrication of the drum assembly, including precision laser cutting, CNC bending for complex geometries, shot blasting for surface preparation, and industrial-grade painting to ensure durability, corrosion resistance, and aesthetic consistency.
The Ask: Build at Scale Without Sacrificing Standards
Pi Green needed a manufacturing partner who could take full ownership of the drum assembly as volumes climbed:
- Tight tolerance drum assembly needed precision fabrication
- Supplier network couldn’t scale or ensure consistency
- Surface finish issues due to DFT variation in painting
- Bottlenecks during volume ramp-up
- Needed a partner, not just a vendor, to co-own outcomes
The Challenge: Scaling Sustainably Without Compromise
At the heart of Pi Green’s Carbon Cutter is a drum assembly that demands precise fabrication, critical tolerance controls, and robust surface treatments. While the team had an early supplier network in place, they soon found themselves constrained by limited production capacity and inconsistent quality.
Dry Film Thickness (DFT) for painting and coating posed another challenge — with environmental performance directly tied to the quality of surface finish. Moreover, the lack of a strong supplier base made it difficult to react quickly to scale-up demands or resolve process bottlenecks. They needed not just a vendor, but a manufacturing partner who could co-own the problem.
How Karkhana Solved It
Karkhana approached the engagement not just as a supplier, but as a strategic partner. The team worked closely with Pi Green to reimagine the manufacturing workflow—right from sourcing to process optimization.
1. Strategic Vendor Development
We took full ownership of the BOM, sourcing every component—metal/plastic enclosures, thermal materials, wire harnesses, and PCB assemblies. This eliminated vendor-chasing for the client and ensured all parts arrived on time and in spec.
2. Quality Engineering at the Core
Maintaining high-dimensional accuracy and material quality was non-negotiable. Karkhana deployed a comprehensive quality plan that included:
- In-house Dye Penetration Testing for weld integrity
- Material Test Certifications for raw input traceability
- Custom gauges and stencils to verify fabrication accuracy
3. Painting & Surface Finish Control
Industrial-grade finishing requires precise paint thickness—too thin, and protection fails; too thick, and tolerances are compromised. Karkhana involved painting application engineers to define and implement DFT standards, ensuring both durability and fit.
4. Unlocking Supplier Capacity
To hit volume targets, we had to remove bottlenecks. This meant:
- Introducing process-level tracking systems
- Collaborating with vendors to rework production layouts
- Scheduling phased deliveries to maintain rhythm while ramping up
The Results: Scale, Speed, and Savings
- 2.5× increase in production capacity
- ~0% manufacturing rejections
- 20% cost savings from optimized sourcing
- 50% reduction in overall turnaround time
Outcome Overview
The clean tech revolution can’t happen without reliable, scalable manufacturing partners. At Karkhana, we’re proud to help pioneers like Pi Green Innovations take their prototypes off the lab bench and into the real world—where they can make the biggest impact.
Whether you’re building EVs, medical devices, or sustainable energy products, we’re here to help you scale confidently and responsibly.
Testimonials
At Pi Green Innovations Pvt Ltd, we are building sustainable solutions for a greener future through our patented carbon cutter technology. Karkhana has played a pivotal role as a strategic partner in streamlining our manufacturing supply chain. Acting as a one-stop solution for our challenges, Karkhana has taken away our hassle of managing multiple stakeholders in the supply chain and enabled us to completely focus on our core business operations.
