Case Studies

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Delivering A Precision Manufacturing Campus For A Global Electronics Major TD Connex

OVERVIEW

TD Connex, a Singapore-headquartered global precision manufacturing company, established its first Indian manufacturing presence at Greenbase-Horizon Industrial Park Oragadam as part of its diversification strategy. The project marks TD Connex’s strategic expansion into India to serve global consumer electronics, mobile device, relay electronics, and medical electronics customers across the USA and Europe.

Greenbase-Horizon delivered a multi-phase, Built-to-Suit (BTS) manufacturing campus, engineered to support high-precision plastic and metal component manufacturing with stringent global quality, safety, and FM compliance standards. The campus has evolved through multiple expansion phases – demonstrating Horizon’s ability to scale infrastructure in line with a client’s rapidly growing and diversifying business requirements.

SECTOR

Engineering Sector

COMPANY OVERVIEW

Founded in Singapore, TD Connex is a global leader in high-precision plastic and metal component manufacturing for consumer electronics, particularly mobile phones. The company serves leading global technology brands in the USA and Europe and operates one of its largest production hubs in Xiamen, China, supplying high-volume, high-tolerance components for mobile and electronics applications.

To mitigate geopolitical risk and strengthen supply chain resilience, TD Connex adopted a China+1 strategy, identifying India – specifically Chennai’s Oragadam industrial corridor – as a strategic manufacturing base due to its mature electronics ecosystem, skilled workforce, and export connectivity.

TD CONNEX ORAGADAM FACILITY: A CLOSER LOOK

TD Connex’s manufacturing campus at Greenbase-Horizon Industrial Park Oragadam, represents the company’s first and largest presence in India, developed in multiple stages to support evolving business lines. Phase I: 80,000 sq ft high-precision manufacturing facility for plastic and metal components used in mobile phones. Phase II: Expansion of ~200,000 sq ft in a separate block for Relay Electronics and Medical Electronics manufacturing. Phase III: ~100,000 sq ft Built-to-Suit facility developed specifically for electronics component manufacturing. The cumulative development reflects Horizon’s ability to deliver scalable infrastructure, aligned precisely to process, equipment, and compliance needs across business verticals.

KEY FEATURES (ICONS)

• 380,000+ sq ft total manufacturing area across phases
• 12m eave height for high-precision shopfloor operations
• 23m bay width with 5T EOT crane capacity
• FM-compliant flooring (5T/sqm ground floor, 1T/sqm mezzanine)
• 300 lux lighting with complete fire-fighting systems
• 2 dock doors with dock levellers + 1 drive-in shutter
• Mezzanine floor across 2/3rd of the facility for upper shopfloor
• Dedicated HT power capacity of 2,500 KvA

GREENBASE-HORIZON’S SOLUTION: THE KEY HIGHLIGHTS

Efficient Design and Layout

Every feature of the TD Connex facility was designed around precision manufacturing, process efficiency, and safety. The Greenbase-Horizon engineering team worked closely with TD Connex’s global operations teams to translate stringent electronics manufacturing requirements into a tailored, scalable Built-to-Suit solution.

• ~380,000 sq ft total built-up area delivered across phases within Greenbase-Horizon Industrial Park Oragadam.
  • Multi-phase campus planned to support electronics manufacturing for mobile phone components, relay electronics, and medical devices.
  • Optimised 23m bay width enables flexible equipment layouts and uninterrupted production line movement.
  • 12m eave height across manufacturing zones provides adequate clearance for precision machinery, automation, and ventilation.
  • EOT crane–ready structure with 5 t crane capacity supports safe movement of tooling and heavy equipment.
  • FM-compliant industrial flooring designed for 5 t/sqm UDL on ground floor and 1 t/sqm on mezzanine ensures durability under multi-shift operations.
  • Mezzanine floor integrated across approximately two-thirds of the facility to maximise usable production and assembly space.
  • 300 lux illumination levels across shopfloor areas support high-precision electronics manufacturing standards.
  • Dock infrastructure includes 2 dock doors with dock levellers and 1 drive-in shutter for efficient inbound and outbound logistics.
  • Dedicated HT power infrastructure of ~2,500 kVA ensures uninterrupted operations for high-load manufacturing equipment.
  • FM-compliant fire protection systems with ~90 KL underground water storage, hydrants, and sprinklers meet global safety norms.
  • Process-led internal circulation planning ensures clear segregation of raw material movement, production zones, and finished goods flow.
  • Separate inbound and outbound security blocks with motorised access control enhance safety and traffic discipline.
  • Perimeter fencing and controlled site access reinforce security and operational integrity.
  • Infrastructure planned with future scalability in mind, allowing seamless expansion and process upgrades without disruption.
  • G+1 office and support spaces integrated to enable operational oversight and administrative efficiency.
  • Campus-level planning ensures alignment with TD Connex’s global manufacturing, quality, and compliance standards.

Strategic and Well-Connected Location

Located within Greenbase-Horizon Industrial and Logistics Park at Oragadam, TD Connex’s manufacturing facility sits at the centre of South India’s most established electronics and advanced manufacturing corridor. The site benefits from direct access to the Oragadam–Sriperumbudur Industrial Belt, with strong road connectivity via NH-48 (Bengaluru–Chennai Highway), the Chennai Outer Ring Road, and key state highways, enabling efficient movement of inbound components and outbound finished electronics. Proximity to Chennai International Airport (~40 km) supports time-critical shipments, while access to Chennai and Ennore Ports (~55–65 km) enables export-oriented operations. The location is embedded within a mature ecosystem of automotive, electronics, and precision engineering OEMs and suppliers, and is directly adjacent to the Hiranandani Township, offering access to housing, social infrastructure, and workforce amenities. Together, these advantages provide TD Connex with a resilient, scalable, and people-centric manufacturing base aligned with its global expansion strategy.

Solution-First, Built-to-Suit Delivery

The TD Connex engagement was anchored in a solution-first, process-led development approach, focused on aligning facility design with the operational requirements of electronics manufacturing and high-precision assembly. Rather than adapting a generic industrial shell, Greenbase-Horizon worked closely with TD Connex’s engineering and operations teams to translate production workflows, material movement, and quality-control needs into a purpose-built facility configuration. Design decisions were driven by efficient bay planning, optimised utility zoning, and clearly segregated process areas to support controlled manufacturing environments and smooth internal logistics. Infrastructure planning prioritised flexibility and future scalability, with layouts structured to accommodate evolving production lines, testing requirements, and technology upgrades. By integrating statutory, safety, and compliance considerations early in the design phase, the project enabled faster approvals and uninterrupted execution. The outcome is a Built-to-Suit facility that reflects TD Connex’s operational precision, supports rapid scale-up, and delivers long-term reliability within a globally benchmarked industrial park.

Rapid Turnaround Time

After design finalisation, Greenbase-Horizon committed to an accelerated delivery schedule aligned with TD Connex’s strict operational timelines and customer commitments. To meet these requirements, construction was executed with multiple work fronts and additional resource deployment, enabling rapid progress across civil, structural, and utility scopes. The core facility was completed in a record 4–5 months from the start of construction, allowing TD Connex to commence its internal fit-out activities without delay. Final handover was achieved within a further 1–2 months, resulting in an overall project delivery timeline of approximately 6–7 months. This tightly managed execution ensured that TD Connex could proceed with equipment installation, trials, and production readiness as planned, reinforcing Greenbase-Horizon’s capability to deliver time-critical, Built-to-Suit industrial facilities without compromising on quality or compliance.

ESG-Aligned & People-Centric Unit

The TD Connex facility at Greenbase-Horizon Industrial Park Oragadam is designed to be 100% ESG-aligned, embedding sustainability principles across construction, building design, and daily operations.

• Environment-friendly construction materials with low carbon emissions were used to minimise embodied carbon impact.
  • 3–4 star-rated electrical and air-conditioning fittings enhance energy efficiency and operational reliability.
  • Extensive natural daylighting through roof and wall openings, combined with effective ventilation design, significantly reduces dependence on mechanical ventilation systems.
  • Solar-ready roof design enables future installation of rooftop solar panels, supporting the use of renewable energy.
  • Topography-led site planning leverages the natural slope of the land, minimising soil cutting and filling and reducing environmental disturbance.
  • Dual plumbing system with separate domestic and flushing lines ensures efficient water use and conservation across the facility.
  • Sustainable design and implementation practices collectively support reduced resource consumption and long-term environmental responsibility.

ON A FINAL NOTE

The TD Connex–Greenbase-Horizon partnership at Oragadam exemplifies Horizon’s capability to deliver process-driven, scalable, and globally benchmarked manufacturing infrastructure for precision-led industries. By supporting TD Connex, through a multi-phase, Built-to-Suit campus delivered at speed and with uncompromising compliance, the project reinforces India’s growing role in global electronics manufacturing.

This case study reflects Horizon’s strength in engineering complexity, enabling rapid expansion, and creating future-ready industrial ecosystems that support long-term global manufacturing ambitions.

Built-to-Suit Manufacturing Facility for a Global Commercial Vehicle Component Leader

OVERVIEW

JOST Werke AG, a Germany-based global leader in vehicle connection systems, established its first South India manufacturing facility at Horizon Industrial Park, Oragadam (Chennai) to expand its production footprint in India. The new facility primarily manufactures Quicke front loaders, backhoes, and agricultural equipment attachments, complementing JOST’s existing Jamshedpur operations.

This Built-to-Suit (BTS) project spans 206,000 sq ft, comprising 135,000 sq ft of shop floor space, 40,000 sq ft of office area, and 30,000 sq ft of utilities, with an additional 25,000 sq ft later added for expanded production. Designed and delivered by Horizon, the facility integrates high-performance industrial design, process-led space planning, and robust infrastructure to support JOST’s heavy-equipment manufacturing processes and global quality standards.

SECTOR

Automotive and Auto Components

COMPANY OVERVIEW

JOST Werke AG: Founded in 1952 in Neu-Isenburg, Germany, JOST is a world-leading producer and supplier of safety-critical systems and components for commercial vehicles. The company’s product portfolio covers both On-Highway (transportation) and Off-Highway (agriculture and construction) applications. With more than 7,500 employees, operations in over 35 countries, and listings on the Frankfurt Stock Exchange (Prime Standard), JOST continues to lead through innovation, reliability, and engineering excellence.

JOST ORAGADAM FACILITY: A CLOSER LOOK

The JOST Oragadam facility represents a high-performance manufacturing hub built to exacting standards, combining functional precision with operational scalability to support the company’s agricultural equipment business in India.

Features (displayed with icons)

• 206,000 sq ft total built-up area, including shop floor, office, and utilities
  • 23 m bay width with single 10 t EOT crane for assembly operations
  • 12 m roof height at eaves ensures efficient vertical clearance
  • Six loading docks with dock levellers and two drive-in shutters
  • 300 lux industrial lighting and full fire-fighting system
  • Specialised civil works for ETP, LOT, gas bank room, and paint booth structure
  • 2,000 kVA HT power connection supporting production and utilities

Horizon’s Solution: The Key Highlights

Efficient Design and Layout

• 206,000 sq ft total built-up area, including 135,000 sq ft of shop floor, 40,000 sq ft of office space, and 30,000 sq ft of utilities, later expanded by 25,000 sq ft for additional production.
  • 23 m bay width engineered to accommodate a 10 t EOT crane, enabling smooth lifting and assembly operations.
  • 12 m roof height at eaves ensures clear vertical movement and optimal air circulation.
  • Epoxy flooring provided in critical process zones to enhance surface durability and safety.
  • Dedicated utility zones house the LOT, compressor, gas bank, and ETP, with optimised layouts to match production flow.
  • Specialised civil foundations designed for heavy machine installation and vibration control.
  • Custom-designed paint booth structure integrated within the main process layout for seamless workflow.
  • Six loading docks equipped with dock levellers and two drive-in shutters ensure efficient material handling.
  • Lighting designed to achieve 300 lux across the shop floor, supported by a full fire-fighting and alarm system.
  • Dedicated power infrastructure with 2,000 kVA HT connected load ensures uninterrupted operations.
  • Separate inbound and outbound gates with motorised access controls provide safe vehicle segregation.
  • Independent fencing and security blocks reinforce site safety and controlled access.
  • G+1 office block adjoins the shop floor, enabling direct supervision and operational coordination.
  • Design optimisations by the Horizon’s engineering team improved space utilisation for the paint booth and utilities, reducing redundancy and improving flow efficiency.
  • Ample parking zones for two- and four-wheelers ensure smooth internal traffic circulation.

Strategic and Well-Connected Location

Located within Horizon Industrial Park at Oragadam, the JOST manufacturing facility is strategically positioned in the heart of South India’s automotive and engineering hub. The park sits along the Oragadam–Sriperumbudur Industrial Corridor, offering seamless connectivity to major OEMs and Tier-1 suppliers. Direct access to NH-48 and NH-32 ensures efficient movement of inbound steel, castings, and components, while proximity to Chennai Port (~60 km) and Chennai International Airport (~40 km) supports domestic dispatches and exports. Surrounded by over 50 Fortune 500 companies, the park offers a mature ecosystem of suppliers and skilled workforce availability. The adjoining 300-acre Hiranandani Township provides world-class residential, healthcare, and retail amenities, enhancing employee convenience and wellbeing.

Solution-First Methodology: Built-to-Suit, Process-Led Onboarding

The engagement between JOST and Horizon was rooted in a process-led engineering approach, ensuring that every design element served an operational purpose. The 23 m bay width and 12 m eave height were designed to support precise lifting and assembly requirements for heavy equipment manufacturing. Collaborative design reviews optimised the positioning of the EOT crane, paint booth, and utility zones for uninterrupted workflow. The decentralised power layout and specialised civil foundations were planned early to reduce vibration risks and ensure equipment stability. Leveraging the site’s natural slope minimised cut-and-fill, reducing both cost and environmental impact. This integrated design methodology resulted in a Built-to-Suit facility tailored to JOST’s safety, efficiency, and scalability needs.

Partnership and Compliance Excellence

The partnership between Horizon and JOST was defined by transparency, compliance, and alignment with global standards. Horizon managed all civil, MEP, and statutory approvals to meet JOST’s EHS and quality protocols. The team ensured early clearance for utilities, ETP systems, and HT power distribution, enabling timely commissioning. Throughout the build phase, Horizon maintained strict adherence to labour safety, environmental regulations, and statutory documentation, ensuring a fully compliant handover. The collaboration exemplifies a delivery model built on mutual trust, accountability, and long-term operational alignment. Hear from JOST on their experience partnering with Horizon. <Link>

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Rapid Turnaround Time

Following design finalisation,Horizon executed JOST’s project within an accelerated six-month schedule, meeting all milestones without compromising quality or compliance. Parallel work streams were adopted to expedite structural, MEP, and utility installations, supported by on-site resource mobilisation and continuous supervision. The facility’s civil works and service installations were completed within 4–5 months, followed by final fitout and equipment commissioning – enabling JOST to commence production ahead of schedule and align its expansion with customer demand timelines.

Value-Added Support

Horizon worked closely with JOST’s operations team to ensure a smooth transition from construction to production. Early coordination across utility handovers, EOT installation, and commissioning phases helped achieve timely ramp-up and operational readiness.

ESG-Aligned & People-Centric Facility

Sustainability and employee wellbeing form the foundation of JOST’s Oragadam facility design. The project adheres to 100% ESG-aligned standards, integrating energy-efficient and resource-conscious systems across all functions.
• The park is IGBC Platinum Pre-Certified.
• Low-emission construction materials and 3–4 star-rated electrical systems reduce operational carbon footprint.
• Roof structure designed for future solar panel integration to enhance renewable energy use.
• Ample natural daylighting and ventilation reduce mechanical cooling demand.
• Dual plumbing network for domestic and flushing water ensures reuse and conservation.
• Natural slope grading minimises earthwork and promotes stormwater recharge.
• Landscaped green areas, canteen, shaded rest zones, and designated parking spaces enhance worker safety and comfort in multi-shift operations.

ON A FINAL NOTE

The JOST–Greenbase-Horizon partnership at Oragadam stands as a benchmark for precision-led, sustainable industrial development in India’s automotive and agricultural equipment sector. Combining JOST’s manufacturing expertise with Greenbase-Horizon’s design intelligence, the facility demonstrates how Built-to-Suit infrastructure can align global production standards with local execution agility. It reinforces Greenbase-Horizon’s position as a trusted partner in developing high-performance, future-ready industrial ecosystems for world-class manufacturers.

Fully Customised Factory For A Global Automotive Components Leader

OVERVIEW

Yazaki India, a wholly owned subsidiary of Japan-based Yazaki Corporation and a global leader in automotive wiring harness systems, expanded its manufacturing footprint in Tamil Nadu with a new built-to-suit facility at Horizon Industrial Park, Chengalpattu near Chennai. This is Yazaki’s third facility with Horizon, with the first being a 2.6 lakh square feet plug and play factory in 2023 at Horizon Industrial Park Hosur, which needed minimal customisation, and followed by their second a 2.6 lakh square feet manufacturing facility in Farukhnagar NCR in March 2024. 

Horizon Industrial Park, Chengalpattu, a 51-acre Grade-A industrial and warehousing park with a planned leasable area of 1.3 million sq ft. Yazaki’s campus spans approximately 348,800 sq ft of built-up area, purpose-designed for high-volume wiring harness manufacturing. The project reflects Horizon’s solution-led approach to delivering compliant, scalable, and ESG-aligned manufacturing infrastructure for global OEMs.

SECTOR

Automotive component manufacturing

COMPANY OVERVIEW

Yazaki Corporation: Established in 1941, Yazaki is among the world’s leading automotive component manufacturers and a global leader in wiring harness systems, with nearly 30% global market share. The company operates in 46 countries, employs over 240,000 people worldwide, and serves major automotive OEMs across conventional and electric mobility segments.

Yazaki India: Established in 1997, Yazaki India operates 11 manufacturing plants and 2 technical centres across 8 locations, employing over 12,000 professionals. The company manufactures wiring harnesses, injection-moulded components, and electronic products for both domestic and global markets. The Chengalpattu facility marks Yazaki’s continued expansion into strategically located industrial clusters in Tamil Nadu.

YAZAKI’S CHENGALPATTU FACILITY: A CLOSER LOOK

The tailor-made manufacturing unit is designed to meet Yazaki’s operational, safety, and workforce requirements while enabling future scalability.

Features (displayed with icons)

• 
  Dedicated wiring harness manufacturing facility designed for ~3,000 employees
  • 12 m clear eave height for efficient workflow and ventilation
  • Floor load capacity of up to 6 t/sqm (UDL)
  • Multiple dock pits with dock levellers and side-loading platforms
  • G+1 office block directly adjoining the shopfloor
  • Dedicated 150 KLD STP, utility blocks, RO plant room, and scrap handling areas
  • Open parking areas spanning 35,780 sq ft for cars, two-wheelers, and buses
  • On-site creche (350 sq ft) and medical room (~480 sq ft) dedicated for Yazaki employees

HORIZON’S SOLUTION: THE KEY HIGHLIGHTS

Efficient Design and Layout

The Yazaki Chengalpattu facility was engineered to optimise production efficiency while ensuring safe segregation of people, materials, and utilities.

• Total built-up area of ~348,800 sq ft, comprising space for manufacturing and storage, a G+1 office block (~51,700 sq ft), and dedicated utility structures.
  • 12 m clear-height PEB structure with skylights covering approximately 5% of the roof area to maximise daylight utilisation.
  • Bay spacing of 8.0 m on the eaves side and 8.49 m on the gable side ensures structural efficiency and layout flexibility.
  • Three external docking platforms with a total of 11 dock pits/dock levellers, along with two side-loading platforms for logistics operations.
  • One drive-in shutter (4.0 m × 5.0 m) enables direct material movement for select processes.
  • 16.5 m wide heavy-duty concrete apron designed to withstand high-frequency truck and bus movement.
  • Two-track sliding windows with MS grills and mesh protection provided on all non-docking elevations.
  • Roof monitor and louvre systems designed to deliver 4–6 air changes per hour (ACPH) across the shopfloor.
  • Roof safety harness lifelines installed along the roof periphery and ridge ventilator for safe maintenance access.
  • Separate man-entry and truck-entry gates, each controlled by dedicated security cabins, ensure safe traffic segregation.
  • Separate worker entry with MS railing, platform, steps, and canopy, segregated from office and material movement.
  • Additional washroom blocks designed to serve a daily population of approximately 2,000 employees.
  • Dedicated 150 KLD STP, RO water systems, and enhanced domestic, flush, and filtered water storage.
  • G+1 office block adjoins the manufacturing area, enabling direct administrative access and operational oversight.

Strategic and Well-Connected Location

Located at Horizon Industrial Park, Chengalpattu, the Yazaki facility benefits from strong regional connectivity and proximity to Tamil Nadu’s major automotive and electronics manufacturing clusters located in the Oragadam and Sriperumbudur industrial corridors. The park, located along Chennai-Trichy Highway enables efficient movement to Chennai and surrounding industrial corridors. The site is located about 66 km from Chennai Port and 50 km from Chennai International Airport, supporting both domestic distribution and export logistics. With improved road infrastructure and the development of nearby SIDCO industrial estates, Chengalpattu continues to emerge as a key manufacturing hub.

Solution-First Methodology: Built-to-Suit, Process-Led Onboarding

Horizon adopted a process-led, built-to-suit approach, aligning the facility’s design with Yazaki’s wiring harness manufacturing workflows. Early coordination ensured efficient zoning of manufacturing, utilities, office spaces, and logistics interfaces. Custom provisions such as dedicated dock infrastructure, drive-in access, segregated entries, and utility enhancements were integrated from the design stage to support smooth operational ramp-up. The resulting facility balances efficiency, safety, and long-term adaptability.

Partnership and Compliance Excellence

Project delivery followed a structured compliance framework aligned with Yazaki’s operational standards. Horizon ensured that all required statutory approvals – including planning approvals, fire NOC, environmental clearances, and pollution control consents – were obtained ahead of handover. Safety, quality, and regulatory compliance were maintained throughout execution, enabling Yazaki to commence operations within a fully compliant manufacturing environment. Mr. P. V. Raju, CEO of Yazaki India, affirmed the partnership’s value: “After evaluating several industrial developers, we chose to partner with Horizon, and they supported us in meeting our timely-delivery commitment to our customers … Horizon emphasizes quality infrastructure and gives us a dust-free environment which is crucial for manufacturing high quality products.”

Rapid Turnaround Time

The Yazaki facility was delivered within an overall 12-month project timeline, with all milestones – including dry access and final handover – achieved as per agreed schedules. Parallel execution of civil, structural, and infrastructure works enabled timely completion without deviations, allowing Yazaki to proceed with production planning as scheduled.

ESG-Aligned & People-Centric Facility

Sustainability and workforce wellbeing are embedded into the Yazaki’s factory design.
• Roof structure designed for future rooftop solar power integration.
• Energy-efficient LED lighting and 3-star-and-above rated motors and pumps.
• Dual plumbing system with separate lines for domestic and flushing water.
• 150 KLD STP with 100% treated water reuse for flushing and landscaping.
• Rainwater harvesting pits and a recharge pond integrated into site planning.
• Skylights and continuous louvres reduce dependence on mechanical lighting and cooling.
• On-site canteen, creche, medical room, shaded walkways, and organised parking enhance employee comfort and safety.

ON A FINAL NOTE

Yazaki’s wire harness manufacturing facility in Chengalpattu demonstrates how thoughtfully planned, built-to-suit industrial infrastructure can support global manufacturing standards while remaining scalable, compliant, and people-centric. Delivered within a growing Grade-A industrial park, the project reinforces Horizon Industrial Parks’ role as a trusted development partner for leading automotive OEMs and supports Yazaki’s continued expansion in India’s evolving manufacturing landscape.

Re-Engineering to Deliver an Enhanced Distribution Center for Rhenus Logistics

RE-ENGINEERING TO DELIVER AN ENHANCED DISTRIBUTION CENTER FOR RHENUS LOGISTICS
Redefining supply chain excellence for a leading global home furnishings retailer

OVERVIEW
The partnership between Rhenus Logistics, a global contract logistics leader, and Horizon Industrial Parks in the Delhi NCR, showcases a new model for high-stakes market entry in India. Rhenus required compliant infrastructure and scalable capacity to serve its diverse multi-client portfolio. Developed within Horizon’s 108-acre, IGBC Platinum-certified park at Farukhnagar, this partnership enabled a multinational home & lifestyle retailer’s first fully outsourced Customer Distribution Centre (CDC) in India – a feat that required extraordinary agility, precision, and sustainability alignment. The client sought a facility that could meet its global standards of efficiency, compliance, and ESG performance. After an exhaustive due diligence process, Horizon Industrial Park’s Farukhnagar I campus was chosen whereby the decisive factor was Horizon’s solution-oriented approach and ability to re-engineer a ready-to-move-in block into customised logistics hub, rapidly adapted with crucial enhancements – such as thermal insulation, tailored dock solutions, and proximity parking. The resulting hub is a blueprint for integrated supply chain excellence, built on a foundation of agility and long-term partnership; a facility that combines global best practices with Indian operational intelligence.

SECTOR:

Third-Party Logistics (3PL)

COMPANY OVERVIEW:

A global logistics powerhouse founded in 1912 in Holzwickede, Germany, Rhenus Group operates across 70+ countries, employing over 40,000 professionals. As part of the Rethmann Group, it provides end-to-end logistics and supply chain solutions including contract logistics, air and ocean freight, project logistics, and last-mile distribution. In India, Rhenus has emerged as a key player in the organised logistics space, recognised by the AITWA Nation Builder Award for its contribution to national infrastructure development. The end client is a global home furnishing giant, with over three decades of sourcing experience in India and an expanding retail presence. Their North India CDC at Farukhnagar represents its next phase of e-commerce and distribution growth. The facility supports over 7,000 SKUs across home furnishing categories, leveraging Rhenus’s digital WMS-EDI platform to power doorstep deliveries across Delhi-NCR. This CDC marks the client’s transition from in-house logistics to a fully outsourced, technology-integrated model designed for scale.

RHENUS LOGISTICS FACILITY: A CLOSER LOOK
The facility – a ready-to-move-in block delivered by Horizon Industrial Parks – was strategically enhanced to meet the demands of high-velocity, multi-shift 3PL operations and the specific requirements of the client’s furniture and e-commerce logistics.
Icons
* Dock-rich facility with 19 loading bays
* High-density storage with ~32,000 pallet positions
* 13 m clear eave height for vertical racking
* FM2-compliant flooring (5 T/sqm UDL)
* EV-ready infrastructure supporting last-mile delivery
* Strategic NCR location with multi-highway access

HORIZON INDUSTRIAL PARKS’ SOLUTION: THE KEY HIGHLIGHTS
• Efficient Design and Operational Layout
Rhenus’ operations required maximizing storage density and throughput – challenges addressed through superior technical specifications:
• Pallet Capacity & Throughput: The facility is dock-rich, featuring 19 loading bays and a capacity for ~32,000 pallet positions. The node is equipped bespoke enhancements like dock pits and movable dock lights to facilitate rapid vehicle turnaround and safe loading operations, even during night shifts and peak seasons. This design ensures high cube utilization and resilience during peak periods.
• Structural Efficiency: The unit features a high 13m eave height, crucial for Rhenus to install optimal vertical racking configurations and maximize storage density.
• Floor & Flow Performance: FM2-compliant flooring with a 5T/sqm Uniformly Distributed Load (UDL) was provided, ensuring enhanced flatness and durability essential for high-frequency, multi-shift MHE operations.
• Worker Comfort: Horizon provides roof and wall insulation to the units to ensure thermal comfort on the floorplate, a key factor for productivity and employee retention in a multi-shift environment, setting our industrial spaces apart.
• Customization: The entrance was custom-designed to align with Rhenus’ operational and branding guidelines, demonstrating a commitment to a “right-fit” solution over a generic facility.
• Strategic and Well-Connected Location
The Farukhnagar park enables Rhenus to operate at the nerve center of North India’s consumption hub.
• Located near IMT Manesar and Gurugram, the park offers crucial proximity to manufacturing and high-density consumer markets in NCR. The location provides direct access to key corridors, including the NH-48 (Delhi-Jaipur Highway) and the Kundli-Manesar-Palwal Expressway (KMP), the State Highway 15A (SH 15A), essential for efficient first-mile and pan-North India distribution. Horizon’s park co-locates Rhenus Logistics with blue-chip companies stabilizing the shared labour pool and service ecosystem. The site’s proximity to Indira Gandhi International Airport (IGI) (approx. 35 km) is vital for last-mile logistics into the densely populated Delhi-NCR region, supporting the client’s promise of quicker, more cost-effective deliveries.

• Solution-First Methodology:
The engagement went beyond a standard lease, using a “solutioning” methodology that was crucial to Rhenus securing the contract.
• Rhenus secured the initial ~3.5 lakh sq ft lease in 2020 and subsequently launched the CDC (~180,000 sq ft) using the ready-to-move block strategy, avoiding the long lead times associated with full Built-to-Suit (BTS) projects and to align perfectly with the end client’s technical logistics requirements and Rhenus’s operational model. The deal was structured to be cost-efficient. Horizon’s team focused on customization (e.g., dock lights, insulation, floor specification) to ensure the facility met the client’s global standards without adding exponential costs, ultimately giving Rhenus the commercial confidence needed to win the contract.
• Partnership and Compliance Excellence
The relationship is defined by deep collaboration, ensuring operational reliability and global compliance. Marcus Fornell, Director of Warehousing Solutions at Rhenus Logistics India, affirmed, “We don’t see Horizon as a traditional landlord. They’re a real partner – collaborative, agile, and solution-focused. Their proactive approach allowed us to relax and focus on our main business while they handled everything from compliance to timelines.”.
Horizon’s commitment to rigorous due diligence and compliance, validated by the IGBC Platinum status, was non-negotiable for Rhenus to meet the stringent international requirements of their major clients. Horizon has demonstrated the ability to deliver multi-client, high-compliance warehousing, including specialized non-inflammable chemical storage blocks (301,000 sq ft in a separate project near Mumbai), showcasing the depth of its solution capabilities for Rhenus’s diverse portfolio.

• ESG-Aligned & People-Centric Unit
Horizon’s IGBC Platinum-certified park provided the necessary foundation for Rhenus Logistics and the multinational home & lifestyle retailer to meet their global decarbonization and social responsibility goals.
• IGBC Platinum Standard: The 108-acre park is IGBC Platinum Certified, establishing a benchmark for sustainability and compliance.
• EV Infrastructure: The campus is equipped with EV charging stations to support Rhenus Home Delivery’s electric vehicle fleet, enabling the client’s move towards a near-100% EV last-mile delivery model in the NCR.
• Water & Light Efficiency: The facility incorporates rainwater harvesting systems and energy-efficient skylights (covering 3-5% of the roof area) to maximize natural daylight and reduce reliance on grid power.
• Workforce Experience: Horizon re-organized parking near the unit and designed the facility with human-centric amenities like restrooms, sports arenas, medical facilities, etc.

ON A FINAL NOTE
The Rhenus-Horizon partnership at Farukhnagar embodies the new face of India’s industrial logistics: solution-driven, ESG-aligned, and globally benchmarked. It proves that infrastructure can be a strategic differentiator – not just a service.
By merging Rhenus’ logistics precision, the global home and lifestyle brand’s retail scale, and Horizon’s development expertise, this project sets a gold standard for integrated supply chain ecosystems. It is a blueprint for future-ready industrial partnerships – where global ambition meets local execution, sustainability meets scalability, and partnership becomes the new currency of growth.

Integrated Manufacturing Hub For A Global Wind Energy OEM

Integrated Manufacturing Hub For A Global Wind Energy OEM

Overview
Vestas consolidated its India operations into a single, expandable manufacturing hub at Horizon Industrial Park, Oragadam (Chennai). The brief demanded a process-led facility capable of handling ultra-heavy assemblies (nacelles, hubs) alongside electronics-grade converter lines and generator assembly – within one integrated campus. Horizon delivered a built-to-suit solution that aligned civil, MEP and yard engineering to Vestas’ production flows: dual-level EOT crane systems, zoned heavy-duty floors, segregated high-side power, climate-controlled converter halls, differentiated dock/plinth logic for inbound and outbound, and ESG-first site planning. The result is a future-ready plant that elevates India’s role in Vestas’ global supply chain while advancing sustainability and workforce outcomes.

Sector:
Integrated wind turbine component manufacturing for the renewable energy industry
Company Overview:
Vestas: A Danish global leader in wind energy solutions (founded 1945; HQ Aarhus), designing, manufacturing, installing and servicing wind turbines worldwide. In India, Vestas announced a new nacelle & hub manufacturing factory in Chennai (2019) and added a converter factory in the same market (2020), reinforcing the country as a regional manufacturing base.
Vestas enables global wind OEM programmes in India and export markets. Vestas’ India industrialisation supports domestic renewables targets while supplying regional demand; the Chennai hub consolidates legacy sites into a scalable, optimised campus.

Objectives
This integrated manufacturing campus for Vestas at Horizon Industrial Park, Oragadam, has been meticulously engineered to align with the company’s complex, multi-process operations. The facility integrates heavy assembly, converter production, and generator manufacturing within a single, process-led environment optimised for performance, safety, and sustainability.

Objectives Overview
520,000 sq ft expansive open yard for heavy-component storage
Dual-level EOT crane systems (80t, 35t, 20t, 15t, 5t)
Staggered roof heights maximise clear spans and natural ventilation
Heavy-duty, FM-grade flooring with zoned slabs with 5t, 7.5t, and 10t UDL capacities
20 m inbound dock height and 0.30 m high outbound plinths
3,000 kW HT infrastructure with decentralised electrical rooms
Converter halls maintain 20°C for electronics QA.

Horizon’s Solution: The Key Highlights

Efficient Design and Layout
Each feature of the Vestas facility demonstrates a high level of engineering precision and adaptability, enabling seamless integration of mechanical and electrical production lines within one advanced campus.
Total built-up area of ~350,000 sq ft accommodates dedicated blocks for nacelle and hub assembly (190,000 sq ft), converter production (100,000 sq ft), and generator assembly (60,000 sq ft).
A 520,000 sq ft open yard and 250,000 sq ft finished goods (FG) area support heavy-component staging, pre-assembly, and dispatch operations across the 27-acre campus, with reinforced surfaces and ample turning radii for trailers and SPMTs.
The main assembly building is equipped with dual-level EOT crane systems (80 t, 35 t, 20 t, 15 t, 5 t) across bays, allowing parallel lifting operations and uninterrupted production flow.
Large clear spans and column-free bays create unimpeded movement zones for nacelles and hubs weighing up to 60 tons.
A staggered roof configuration – higher above assembly, lower above warehousing – optimises daylighting, ventilation, and steel tonnage.
FM-grade floors are zoned at 5 t/sqm, 7.5 t/sqm and 10 t/sqm to handle variable process loads while maintaining surface flatness for MHE precision.
Six inbound docks are provided at 1.20 m plinth height for container unloading; outbound bays 0.30 m high facilitate roll-on/roll-off dispatch of completed nacelles.
HT electrical infrastructure of 3,000 kW is distributed through decentralised power rooms, giving operational flexibility and redundancy.
The converter hall maintains 20 °C through precision HVAC systems to safeguard electronics during assembly and testing.
A G+1 RCC office block (~20,000 sq ft) provides direct line-of-sight supervision of shopfloor operations.
Separate inbound/outbound gates, motorised access control and a 360° boundary wall reinforce site security.
Landscaped perimeters and parking zones for four- and two-wheelers ensure organised traffic and workforce comfort.
Strategic and Well-Connected Location
The Oragadam industrial corridor places Vestas at the heart of South India’s manufacturing ecosystem – deep supplier pools (auto/wind), skilled workforce, and multi-modal connectivity for inbound steel/castings and outbound heavy modules. Proximity to national highways, the GST/GWT corridors and Chennai’s ports underpins both domestic dispatch and exports. Strategically located on the NH-48 industrial corridor, Oragadam offers seamless road connectivity to Chennai, Bengaluru, and Sriperumbudur. With proximity to Chennai Port (~59 km) and Chennai International Airport (~39 km), and upcoming rail connectivity via the Avadi–Guduvanchery line, it serves as a key multimodal logistics hub driving South India’s industrial growth.

Solution-First Methodology: Built-to-Suit, Process-Led Onboarding
The engagement prioritised Vestas’ process maps over generic shed geometry. Horizon–Vestas engineering exercises (including benchmarking at a reference Vestas plant) informed value engineering: dual-level roofs for crane envelopes, topography-led dual plinths to cut earthworks and carbon, zoned floor loads matched to stations, and decentralised electricals to minimise plant-wide downtime.

Partnership and Compliance Excellence
A program-managed delivery aligned civil/MEP, HSE and statutory clearances to Vestas’ industrialisation goals in India. The park’s governance and documentation, coupled with Vestas’ global QA and EHS standards, ensured a compliant, scalable platform. The partnership between Vestas and Greenbase-Horizon was defined by transparency, compliance, and shared commitment to global standards, reinforcing long-term partnership continuity and operational trust. Hear from Vestas on their experience partnering with Greenbase-Horizon.

Rapid Turnaround Time
Following design finalisation in February 2020, Horizon and Vestas targeted facility delivery by October 2020 for trial runs and production commencement by December. When construction began, the first wave of COVID-19 brought nationwide restrictions, disrupting material movement and workforce mobilisation. To uphold the committed timelines, Horizon arranged on-site accommodation for its construction teams and secured special permissions to resume work within the park. All labour welfare, provisions, and medical facilities were ensured during the lockdown period. Despite the unprecedented challenges, the 27-acre facility was completed and handed over by early October 2020 – within just six to seven months – enabling Vestas to proceed with trial production as planned.

Value-Added Services
Beyond project delivery, Greenbase-Horizon extended comprehensive facilitation support to ensure Vestas’ operations commenced smoothly and on schedule. The team coordinated statutory licensing processes on behalf of Vestas, enabling timely approvals for production start-up. Greenbase-Horizon also assisted in securing applicable incentives from the Tamil Nadu Government, reinforcing the project’s commercial viability and strengthening Vestas’s long-term presence in the state.

ESG-Aligned & People-Centric Unit
The Vestas Oragadam facility embeds sustainability and workforce wellbeing into its core design, meeting global ESG benchmarks from construction to daily operation.

Natural daylighting and ventilation reduce mechanical cooling loads; energy-efficient LED fixtures and 3- to 4-star-rated electrical fittings optimise consumption, leading to a low-carbon footprint.
Structural provisions allow easy future integration of rooftop solar panels to power operations sustainably.
Separate lines for domestic and flushing water ensure effective resource reuse and minimal wastage and better water reuse.
Extensive open yards and paved aprons accommodate safe staging of heavy components while minimising dust and runoff.
More than 1,500 trees planted, with a total of ~2,500 green cover enhancing microclimate and biodiversity, in a landscaped Miyawaki forest.
Amenities such as canteen, shaded rest areas, and proximity parking improve comfort and retention in multi-shift operations.
Construction used low-emission concrete and locally sourced materials to reduce embodied carbon.
Louvred openings and HVLS fans maintain steady airflow, improving indoor conditions year-round.
Rainwater harvesting pits and stormwater channels integrated across the 27-acre site promote reuse and recharge.

On A Final Note
The partnership between Vestas and Greenbase-Horizon at Oragadam exemplifies the next generation of clean-energy manufacturing hubs in India: solution-driven, ESG-aligned, and globally benchmarked. By combining Vestas’ turbine engineering precision with Greenbase-Horizon’s process-first development approach, the campus positions India as a strategic manufacturing base for wind components – where heavy-duty readiness meets electronics-grade environments, sustainability meets scalability, and partnership becomes the new currency of industrial growth.

Integrated Manufacturing Campus For A Global Composites Leader

Integrated Manufacturing Campus For A Global Composites Leader

Overview
Gurit Wind Technology Pvt. Ltd. – part of Switzerland-based Gurit AG, a global pioneer in composite materials, tooling, and engineering solutions – established its first integrated Indian manufacturing hub at Greenbase-Horizon Industrial Park, Oragadam (Chennai). The project consolidated four distinct business units under one roof – Materials (PET), Kitting, Tooling, and Structural Profiles – to support the company’s global operations across wind energy, marine, and aerospace sectors.
Gurit’s facility is located within Greenbase-Horizon Industrial Park, Oragadam, a 140-acre, 3.3 million sq ft integrated industrial campus. The 16-acre Gurit campus forms part of this larger ecosystem. Greenbase-Horizon delivered a Built-to-Suit (BTS) solution engineered for high precision, heavy-duty tooling, and process-driven manufacturing. The 16-acre campus features over 530,000 sq ft of covered area (Phases I & II) and 370,000 sq ft of open yard, with design optimisations tailored to Gurit’s operational requirements. The result is a world-class facility that aligns with Gurit’s innovation-led manufacturing strategy and reinforces India’s growing role in the global renewable supply chain.

Sector:
Advanced composites manufacturing for the renewable energy industry

Company Overview:
Founded in 1835 and headquartered in Wattwil, Switzerland, Gurit AG is a publicly listed global leader (SIX Swiss Exchange: GURN) in advanced composite materials and solutions. With operations across 20+ countries, the company delivers material technologies, tooling systems, finished products, and engineering services to the wind energy, marine, aerospace, and automotive sectors. Gurit is committed to sustainability through innovation in lightweighting and recyclable materials, making it a key enabler of global renewable growth.

Objectives
The Gurit campus at Greenbase-Horizon Industrial Park is the company’s only fully integrated facility in India, bringing together four major production units – Materials (PET), Kitting, Tooling, and Structural Profiles – within a single manufacturing ecosystem optimised for efficiency, precision, and sustainability.

Objectives Overview

530,000 sq ft built-up area with 370,000 sq ft open yard
EOT cranes up to 32 t for tooling and mould handling
14 m eave height with 28 m bay width for blade mould movement
Heavy-duty 8 t/sqm flooring for plug and mould assembly
10 m × 10 m vertical lift mega doors with 40 m turning radius
5,850 kVA dedicated HT power infrastructure

Greenbase-Horizon’s Solution: The Key Highlights

Efficient Design and Layout
Every feature of the Gurit facility was designed around process optimisation and safety. The Greenbase-Horizon engineering team worked closely with Gurit’s operations teams to develop tailored layouts and technical solutions that address each unit’s unique production needs.

530,000 sq ft total built-up area across two phases, with 370,000 sq ft open yard on a 16-acre site.
Four dedicated business units – Materials (PET), Kitting, Tooling, and Structural Profiles – consolidated under one campus to streamline operations.
Optimised 28m bay width in the Tooling Unit for EOT coverage and parallel mould movement, enabling storage of up to five moulds in parallel.
Tooling Unit equipped with four 32t and two 20t EOT cranes, 14m eave height, and 170m bay length for blade mould handling.
40m turning radius and 10m × 10m vertical lift mega doors facilitate smooth movement and dispatch of 60–70m blade moulds.
Heavy-duty flooring (8t/sqm) across tooling areas supports the movement and storage of large plugs and moulds.
Materials, Kitting, and Structural Profile Units feature 14m roof height (15m × 15m in select zones), 1.20m plinth height, 2 dock shutters, and 1 drive-in shutter for MHE operations.
14m eave height across main production zones provides sufficient clearance for large machinery, improved ventilation, and natural lighting.
Simulation-led design optimisation at the outbound area ensures accurate vehicle movement and turning radii for long moulds.
Use of the site’s natural topography achieved dual plinth levels while minimising earthwork and environmental impact.
Redesigned electrical system with decentralised high-side power setup for greater flexibility and operational reliability.
Dedicated power capacity of 5,850 kVA distributed across four units (3,500 kVA for Materials, 1,350 kVA for Kitting & Structural Profiles, and 1,000 kVA for Tooling).
Specialised civil foundation and containment works for the cyclopentane storage tank ensure compliance with PESO safety norms.
G+1 office block adjoins the production area, providing direct visibility and access to shopfloor operations.
Site designed with separate inbound and outbound gates, independent boundary walls, and dedicated parking for two- and four-wheelers.
Extensive 33% greenbelt with over 1,000 trees enhances microclimate, supports rainwater percolation, and reinforces ESG compliance.
Strategic and Well-Connected Location
Located within Greenbase-Horizon Industrial Park at Oragadam, Gurit’s manufacturing campus lies at the centre of South India’s most dynamic industrial corridor, offering seamless multimodal connectivity for inbound raw materials and outbound finished composites. The site sits along the Oragadam–Sriperumbudur Industrial Corridor, with direct access to NH-48 and NH-32 connecting Chennai, Bengaluru, and Sriperumbudur. Its proximity to Chennai Port (~60 km) and Chennai International Airport (~40 km) supports both domestic dispatch and export operations, while future rail connectivity via the Avadi–Guduvanchery line further strengthens logistical efficiency. Surrounded by a mature ecosystem of automotive, wind, and precision engineering industries, and adjacent to the 300-acre Greenbase-Horizon–Hiranandani integrated township, the location ensures access to skilled labour, housing, and essential social infrastructure – all within a world-class industrial environment.

Solution-First Methodology: Built-to-Suit, Process-Led Onboarding
The Gurit engagement was defined by a deep process-first approach, translating four distinct manufacturing streams – Materials (PET), Kitting, Tooling, and Structural Profiles – into one seamlessly coordinated campus. Instead of adopting a standard industrial layout, Greenbase-Horizon and Gurit co-engineered a configuration that aligned every building envelope, bay span, and utility system with production flow. Design development was driven by simulation-led layout planning for mould movement and turning radii, decentralised high-side electrical systems to ensure operational redundancy, and site grading optimised through natural topography to reduce cut-and-fill and carbon impact. Specialised civil works, such as the integrated foundation for cyclopentane storage and PESO compliance, were incorporated early in design to accelerate statutory approvals and maintain construction momentum. The result is a fully process-led, Built-to-Suit facility that balances operational precision, safety, and long-term scalability.

Partnership and Compliance Excellence
The partnership between Gurit and Greenbase-Horizon was built on transparency, compliance, and shared commitment to operational excellence. A program-managed delivery framework integrated civil, MEP, HSE, and statutory clearances with Gurit’s global safety and quality standards, ensuring timely execution across all four manufacturing units. Greenbase-Horizon’s governance model and documentation supported seamless audit readiness and adherence to PESO and environmental regulations. Beyond construction, the team facilitated bonded licensing and coordinated Tamil Nadu Government incentives, reinforcing long-term commercial viability and compliance alignment. The collaboration reflects a trusted, solutions-driven relationship focused on reliability, sustainability, and scale. Hear from Gurit on their experience partnering with Greenbase-Horizon.

Rapid Turnaround Time
After design finalisation, the Greenbase-Horizon team committed to an accelerated delivery schedule. Despite the challenges of the COVID-19 second wave, construction progressed through meticulous planning and continuous site operations. By housing construction teams within the park, securing permissions for material movement, and maintaining full labour welfare and medical support, Greenbase-Horizon successfully completed and handed over the 530,000 sq ft campus within schedule, allowing Gurit to begin production trials on time.

Value-Added Services
Greenbase-Horizon provided comprehensive facilitation services to ensure a seamless operational start. The team coordinated Gurit’s statutory licensing processes, ensuring timely approvals for production commencement. Greenbase-Horizon also assisted in obtaining Tamil Nadu Government incentives and facilitated the PESO licensing for cyclopentane storage through close coordination with state departments. These efforts reinforced compliance and operational readiness for Gurit’s India launch.

ESG-Aligned & People-Centric Unit
The Gurit Oragadam park is IGBC Platinum Pre-Certified embedding sustainability into its core design, meeting global ESG benchmarks from construction through operations.

100% ESG-aligned construction using low-emission and locally sourced materials to reduce embodied carbon.
3–4 star-rated electrical and HVAC systems ensure high energy efficiency and operational reliability.
Structural provisions enable future installation of rooftop solar panels for renewable power generation.
Natural daylighting and cross ventilation reduce dependence on mechanical cooling systems.
Dual plumbing network for domestic and flushing water promotes reuse and conservation.
Rainwater harvesting structures and slope-optimised site grading enable stormwater recharge and prevent surface runoff.
Extensive landscaping and greenbelt development across 33% of the site, with over 1,000 trees planted, enhances microclimate and biodiversity.
Amenities such as shaded rest zones, canteen, and dedicated parking areas support comfort and safety for multi-shift operations.

On A Final Note
The Gurit–Greenbase-Horizon partnership at Oragadam showcases the evolution of India’s renewable manufacturing infrastructure – process-led, sustainability-aligned, and globally benchmarked. By integrating four business units under one efficient, high-specification campus, the project sets a new benchmark for multi-unit composite manufacturing in India. It reflects Greenbase-Horizon’s ability to translate complex operational requirements into engineered, future-ready industrial ecosystems that accelerate global clean-energy ambitions.

Top Infrastructure Features that Define Grade-A Industrial Parks

Top Infrastructure Features that Define Grade-A Industrial Parks

Overview
Horizon Industrial Parks’ expansion strategy encompasses the acquisition of strategically located brownfield and greenfield assets across India. Leveraging Blackstone’s global expertise, Horizon enhances these assets by implementing superior infrastructure, ensuring compliance, and fostering safer, healthier workplaces with a positive Environmental, Social, and Governance (ESG) impact.
Building upon the successful transformation of Horizon Industrial Park Chakan II, we applied the same strategic redevelopment approach to our project in Patancheru, Hyderabad. This initiative underscores our commitment to enhancing India’s industrial infrastructure by converting underutilised assets into state-of-the-art, Grade A facilities.
Located in the TSIIC Yelumala region near Nagulapalli railway station, Patancheru is a burgeoning industrial hub on Hyderabad’s outskirts. Recognising the area’s strategic significance for manufacturing, e-commerce, and 3PL activities, we embarked on a comprehensive redevelopment plan for our 26-acre park, aiming to align it with global standards and sustainable practices.

Problem:
When Horizon Industrial Parks acquired the 26-acre site in Patancheru, located in the TSIIC Yelumala industrial belt near Hyderabad, the park showed promise due to its location but lacked the essential infrastructure and amenities expected of a modern Grade A facility. Despite its strategic proximity to key industrial zones and the Nagulapalli railway station, the site suffered from poor traffic flow, subpar sustainability provisions, and limited support for safety, security, and employee well-being. This gap presented both a challenge and an opportunity—to transform an underwhelming, operational site into a benchmark facility for efficient, future-ready, and human-centric logistics infrastructure.

Objectives
The objective behind redeveloping the Patancheru industrial park was to holistically transform the site into a Grade A logistics facility aligned with Horizon’s vision of quality, compliance, sustainability, and human-centric design. This meant not only upgrading physical infrastructure but also enhancing operational efficiency, employee experience, and environmental performance. The core goals guiding this transformation thus included:

Objectives Overview
Build robust, compliant infrastructure to support scale and resilience.
Streamline vehicle movement and traffic circulation and enable organised and optimised space utilisation across the facility.
Deliver tangible ESG outcomes through sustainable design by improving energy efficiency and reducing the park’s carbon footprint.
Support tenant productivity and satisfaction through other value-added initiatives.

SOLUTION:
We approached the redevelopment of Patancheru Park as more than a retrofit—it was a deliberate reimagining of what an industrial space could and should be. Guided by a clear objective and grounded in our core pillars of delivering right fitted, hands-on, efficient and sustainable solutions, we undertook a series of targeted interventions across the site. Each measure was more than a physical upgrade but a strategic response to existing limitations, designed to future-proof the park and unlock greater value for tenants, workers, and the wider ecosystem. Here’s how we brought this vision to life—one solution at a time:

Upgraded Roads for Enhanced Vehicle Movement:
The entrance gate area of Patancheru Park has undergone significant improvements with an optimised road gradient and an upgraded road curvature to enhance vehicle movement. The adjusted gradient ensures a smoother transition for trucks and heavy vehicles, reducing strain on engines and minimising acceleration fluctuations. The improved road curvature facilitates seamless turning, reducing the risk of vehicle skidding and congestion. Additionally, all site roads have been marked with road lane markings, directional arrows, designated pedestrian crossings, rumblers, and chevron marking. These upgrades mean improved traffic flow, reduced vehicle wear and tear, and enhanced safety for drivers.

Sustainable Measure for Resource Conservation:
Patancheru Park has integrated multiple sustainability measures to enhance resource conservation and environmental efficiency. The site already had two rainwater harvesting pits, which was a good start. But to better cater to the scale of the facility, we plan to bring the total to 12—out of which five have been constructed. This initiative contributes to the groundwater recharge and reduces surface run-off.

A 500-kW solar panel system has been installed to promote renewable energy usage and significantly lower the park’s carbon footprint once operational. This installation can potentially mitigate 505 tCO₂e which is equivalent to planting approximately 23,000 trees. Dedicated EV charging points—two for four-wheelers and four for two-wheelers—encourage the adoption of electric vehicles, reducing dependency on fossil fuels. The park is equipped with LED streetlights, which consume significantly less power compared to traditional lighting systems, reducing overall electricity usage and maintenance costs.
These initiatives, aligned with IGBC (Indian Green Building Council) requirements, contribute to sustainable operations by conserving water, promoting clean energy, and supporting eco-friendly transportation within the park. This park is thus Platinum rated.

Dedicated Parking Spaces:
We have developed paved truck parking area designed to accommodate heavy vehicles efficiently, ensuring smooth traffic flow and reducing congestion. The parking spaces are clearly marked using thermoplastic paint, which provides durable, high-visibility lane markings for easy navigation. Additionally, we introduced dedicated parking spaces for four-wheelers and two-wheelers which needed to be strategically placed within the existing layout of the premises. These now allow for organised parking and contribute to better utilise these spaces across the park.

Waste Management Measures:
We integrated an efficient waste management system with a dedicated compost pit and waste segregation area to promote environmental sustainability. The compost pit enables the conversion of organic waste into nutrient-rich compost, reducing landfill waste and supporting green landscaping within the park. The segregation area ensures systematic sorting of waste into biodegradable, non-biodegradable, and recyclable categories, streamlining waste disposal and recycling efforts.
This park utilises a manual irrigation system to ensure controlled and efficient water distribution. A smart water meter has been installed to further optimise water consumption and enhance its monitoring across the premises. This advanced system provides real-time data on water usage, helping identify any inefficiencies, detect leaks, and ensure water is used only when necessary.

Enhanced Security and Surveillance:
To safeguard both people and assets, the Patancheru Park now features a comprehensive, 24/7 CCTV network covering all access points, internal roads, loading bays, and peripheral boundaries.
All feeds are centrally monitored from our operations control room, with enhanced visibility on the activities for the on-site personnel so that they may call for timely intervention or reinforcements if required. This proactive approach has not only reduced security incidents by over 40% but also given tenants and their workforce complete peace of mind, knowing that every corner of the park is under vigilant watch.

Enhanced Greenery:
Patancheru Park’s green makeover goes beyond aesthetics—strategically placed landscaped islands now break up paved expanses, guiding traffic flow while creating pockets of shade and cooler microclimates. Native varieties like Lemon grass, Golden Bamboo and flowering shrubs like Tecoma ,Tecomaria ,Caeslapinea, Cestrum reduce runoff and improve soil health, while vertical elevations—clad in climbers like Lonicera , Thunbergia ,Pyrostegia —act as living insulation, lowering adjacent wall temperatures up to 5 °C. Together, these elements—amounting to15% green cover—boost the on-site biodiversity, attract pollinators, and enhance air quality by capturing dust and CO₂. More than just “pretty views,” these landscaped features support worker well-being, reduce the heat-island effect, and reinforce our commitment to sustainable, human-centric design.

Meaningful Social Initiatives:
Horizon’s vibrant social ecosystem is designed to bring people together through meaningful interactions and shared experiences. Events like Agility Day, Safety Week, and Cricket Tournaments are hosted regularly, offering tenants and their teams a chance to unwind, bond, and collaborate outside the workplace. Coupled with festival celebrations, health-awareness activities, and community-building activities, these recreational initiatives strengthen relationships and promote a sense of camaraderie, ensuring the park thrives as both a professional and social community.

Conclusion
In just a few months, the upgradation of Horizon Industrial Park Patancheru has more than delivered. Smoother road gradients and clear lane demarcations have cut average truck turnaround times, while our solar panels are set to offset nearly 15-20% of the park’s power needs. Enhanced lighting and CCTV coverage has driven a drop in safety incidents, and tenant feedback consistently praises both the efficiency gains and the uplifting work environment created by green spaces and community events.
By marrying operational rigor with sustainable design and human-centric amenities, we’ve transformed the site into a best-in-class logistics hub—one that delivers clear cost savings, bolsters ESG credentials, and sets a new standard for what industrial parks can achieve.

Aseptic Carton Manufacturing Facility Delivered for SIG Combibloc

Aseptic Carton Manufacturing Facility Delivered for SIG Combibloc

Overview
SIG Combibloc (SIG) entered the Indian market in 2018 and has since rapidly expanded to add more product lines and customers to their portfolio. The company had been exploring options in India to set-up a large aseptic carton manufacturing facility, with the location choices narrowed down between Pune and Ahmedabad. For this, they also sought a partner in the form of an institutional developer who had suitable land parcels at their desired locations and the capabilities to accomplish this endeavour.
Upon a rigorous market evaluation, SIG selected Horizon Industrial Parks owing to its impressive track record in designing, constructing, commissioning, and managing high-quality, globally compliant industrial parks. Horizon’s commitment to consistently meet standards for human-centric design and sustainability further aligned with SIG’s ESG goals.
The resulting facility is a new, state-of-the-art manufacturing unit fulfilling the company’s primary aim of enhanced production capacity while also providing improved delivery capabilities for SIG’s existing and prospective customers in India. This expansion has strengthened SIG’s logistical efficiency and proximity to its customer base, enabling improved responsiveness to emerging market demands in the region.

Sector:
Aseptic carton packaging manufacturing for the food and beverage industry

Company Overview:
SIG is one of the world’s largest global suppliers of packaging systems for the beverage industry. The SIG Combibloc division handles the manufacturing of aseptic cartons and filling systems. Founded in 1853, SIG is headquartered in Neuhausen, Switzerland; is listed on the SIX Swiss Exchange, and serves customers in over 100 countries.
SIG manufactures aseptic carton packs, bag-in-box packaging and spouted pouches for beverages and food. These are increasingly moving towards using the world’s first aluminium-layer-free aseptic packs with fully renewable materials. The company also produces, operates and maintains packaging machines for the F&B (food and beverage) industry.

Objectives
This bespoke facility for SIG India spanning nearly 7.82 Lakh sq. ft. is spread across 32.6 acres and will be developed in four phases. The SIG facility and its campus have been meticulously designed to optimise efficiency, creating an environment that integrates manufacturing, assembly, and raw material and finished product storage areas within one cohesive space.

Phase – I (~3.41 Lakh sq. ft.), which has already been delivered, is divided into multiple functional areas which include the printing press hall, production hall, finishing area, warehouse, despatch, technical annex, office, canteen, external utility buildings and open utility areas. The office area is situated on a mezzanine floor with a direct access to the canteen building provided via an overhead bridge. The office area also has multiple staircases for access to specific production areas as well as storage areas on the shopfloor. The key points of this project include:

Objectives Overview

Dry access of Phase I provided at 9 months and final handover at 12 months
Large clear spans (up to 50 meters) and heavy-duty mezzanine floors, optimising space and flexibility
Specialised foundations for large, heavy machinery and storage racks
High-capacity HVAC system, cooling towers, and tailored utility piping
State-of-the-art IBMS (Integrated Building Management System) for efficient monitoring and operations
Acoustic enclosures in production area to limit noise levels to 70 dB
30% of the plot designated as open space with 25% vegetation cover

HORIZON INDUSTRIAL PARKS’ SOLUTION: THE KEY HIGHLIGHTS

Strategic and Well-Connected Location
SIG’s new manufacturing facility is situated in Horizon Industrial Park Bhayala near Ahmedabad, Gujarat. Located along the Ahmedabad-Rajkot Highway, the park is well connected to the Western Dedicated Freight Corridor (WDFC) which will link the states along its length from Delhi-NCR to Mumbai’s JNPT to the State of Gujarat. The facility is ~45 kms from Ahmedabad and located near the well-established industrial cluster at Sanand (~33 kms), which hosts more than 500 well-known companies from auto, auto components, engineering, pharmaceuticals, FMCG, and F&B sectors. Furthermore, it is strategically positioned close to some of the major customers for SIG’s aseptic packaging solutions.

Adherence to the Stipulated Timeframe
Horizon completed the Phase I, which includes the external infrastructure, landscape and the utility services successfully as per the agreed timeline. The dry access for this built-to-suit facility was provided to SIG at the 9-month mark, and the final handover was given at the 12-month mark, ensuring that all milestones were met as committed.

Compliance with Local Regulations
In addition to the park’s strategic location, SIG also chose Horizon Industrial Parks for its demonstrated commitment to compliance and adherence to local, state, and national regulations for each of their past and ongoing projects.
All design parameters ensured compliance to LEED Gold certification criteria for the project, and met established standards for environmental sustainability, energy efficiency, and responsible construction practices.
The SIG facility at Bhayala also fulfils all statutory and standard approvals necessary for manufacturing and storage.

Efficient Design and Layout
Each feature of the SIG 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.

The main plant building features large clear spans with no interior columns: 50 meters for the printing hall, 33 meters for the production and finishing halls, and 30 meters for the warehouse area, providing open, flexible spaces.
The clear height is 12 meters throughout the entire structure, with a specific storage area for heavy-duty print reel cylinder racks having 18 meters of clear height.
Pile foundations are used to support the massive loads from the reel cylinder storage racks.
Machine foundations include embedded steel rails in the floor above RCC foundations, with 100mm sunk floor slabs for specific machine profiles and high-performance chemical grouts used after machine installations.
A heavy-duty mezzanine with a load-bearing capacity of 3 KN/square meter is designed for transformers, chillers, pumps, compressors, pressure vessels, and switchgear panels.
The G+1 RCC canteen building is connected via an overhead bridge to the office area on the mezzanine floor of the main plant, ensuring easy access between the two spaces.
The electrical power required for Phase-I operations is 4 MVA, supplied by two 2.5 MVA transformers rated at 400 V. General lighting and electrical cabling are set up with feeder panels for each zone according to functional needs.
A water-cooled HVAC system, with 1,860 TR capacity (four 465 TR VFD-driven screw-type chillers), is designed to handle machine exhaust and provide cooling for the shop floor, office areas, electrical rooms, and the canteen.
A mechanical ventilation system and 24-foot diameter HVLS fans are provided for the warehouse area.
The main HVAC system also includes a 100 TR chiller capacity for process cooling, using a plate heat exchanger.
Four VFD-driven cooling towers, each with a 400 M3/hr capacity, are installed on the roof. An RO plant and softener equipment are provided to treat water and use it for the cooling towers in the HVAC system.
The system includes one 435 CFM VFD-driven screw-type oil-free compressor and two 435 CFM fixed screw-type oil-free compressors, all rated at 8.0 kg/cm², along with air-cooled refrigerant-type air dryers and a 4m³ dry air receiver.
The facility includes an LPG gas bank with a vaporizer, distribution system, and pressure-reducing stations on the shop floor and in the canteen’s wet kitchen.
Utility piping is installed throughout the plant, with tap-off points at floor level based on user requirements.
Acoustic enclosures are installed in part of the production area to absorb noise and limit sound levels to 70 dB outside, from the 110 dB noise produced by the machines inside.
An integrated IBMS (Integrated Building Management System) is used for real-time monitoring of all MEP (Mechanical, Electrical, and Plumbing) services to ensure high operational efficiency.

Phase1 of SIG’s manufacturing plant

ESG-Aligned Manufacturing Unit
Horizon’s approach to ESG aligned in its facility design, material selection and advanced construction practises emphasise 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.
High COP (>5.67, as per AHRI) VFD driven screw type chillers to reduce energy consumption and at par with LEED standards for sustainable design.
All air handling units (AHUs) are equipped with VFD motors for the HVAC system, which adjust speed based on demand, making them energy efficient. 50% of the total capacity of air compressors are also VFD driven for further energy efficiency.
30% of the total plot as open area with 25% vegetation cover as per LEED requirement promoting ecological balance in the micro-environment.
Rainwater harvesting system is installed with a retention pond at the end of the storm water drain system for thorough collection and disposal. This can be reused for other non-potable uses in the facility, reducing dependence on freshwater.
Use of low flow fixtures promotes an optimal use of water, and a dual plumbing system separates water lines for flushing and domestic use. The recycled, treated water is used for toilets and irrigation, further reducing freshwater demand by means of an MBBR type STP.
The evaporator plant uses a ZLD system to treat rejected water (such as from the RO) for maximum recovery of water from waste. The rejected water is re-used for cooling towers for the HVAC system reducing the overall water consumption.
LED lighting fixtures have been installed throughout the facility to meet optimised lux levels for general lighting and minimise energy consumption.
On a Final Note
Working with SIG India has furthered our ever-evolving understanding of managing complex, specialised industrial projects with new valuable insights about the aseptic packaging manufacturing industry. Horizon’s visit to SIG’s plans outside of India, helped us understand their processes and develop an optimal techno-commercial solution for them, with planned expansion in four phases. Horizon created a temporary office space for SIG’s engineering and operations team at the site during the construction of Phase I to facilitate ongoing collaboration between both organisations, resulting in speedier resolution of design and construction queries, ensuring that the project stayed on schedule.

Elevating Standards: High-Efficiency, Human-Centric Industrial Parks

Elevating Standards: High-Efficiency, Human-Centric Industrial Parks

Overview
Horizon Industrial Parks’ expansion strategy includes acquisition of well-located brownfield and green field assets across India. We add value to the acquired operational assets through our access to Blackstone’s global experience in building superior quality infrastructure and service, focus on compliance for creating safer, healthier workplaces and delivering a positive ESG impact.
Despite its strategic location and potential, the Horizon Industrial Park Chakan II, an acquired brownfield asset fell short of the Grade A warehousing standards synonymous with Blackstone’s global logistics real estate portfolio. The facility required comprehensive upgrades to meet the company’s mission of delivering benchmark quality and superior returns and its purpose of providing agile solutions for accelerated customer growth.

Project Overview
One of the maiden operational assets acquired by Horizon Industrial Parks is located at Chakan MIDC (Phase II) in Pune, Maharashtra. While the park, spread across 52 acres, had foundational infrastructure, it lacked the institutional, Grade A features and amenities crucial to fulfilling Horizon’s mission and purpose. This gap prompted a strategic overhaul to enhance the park’s offerings and align it with Horizon’s commitment to quality, customer success and creating humanistic work environments.

Objectives

Enhancing infrastructure and amenities to meet Grade A warehousing and industrial standards.
Incorporating sustainable and efficient solutions to support environmental goals.
Improving safety, accessibility, and aesthetics to attract and retain customers.
Fostering a conducive environment for customer success and growth.

Solution
Horizon Industrial Park Chakan II has today delivered the ambitious vision it started with: to transform a partially constructed asset into a world-class, Grade A industrial park. Designed to meet the demands of manufacturing and logistics companies, the park offers state-of-the-art infrastructure and tailored built-to-suit solutions that rival global centres of excellence. With premium materials, robust construction, and exceptional space customisations, the park delivers reliability and efficiency in record time. Solutions implemented include…

Improved Circulation:
We prioritised upgrading circulation infrastructure to improve functionality, safety, and aesthetics. Key enhancements included the widening of internal roads, ensuring smoother traffic flow for passenger and commercial vehicles alike. To elevate the visual appeal, we introduced landscaped medians and planted greenery along the roadsides, creating a more inviting and environmentally conscious campus atmosphere.

Safety was another critical focus area. We installed clear directional signages, and boom barriers throughout the park, strategically placed to guide drivers and minimise confusion. Block branding was also implemented, allowing tenants and visitors to easily locate specific areas within the expansive campus. These additions enhanced wayfinding and reduced travel time within the park.

The park’s infrastructure supports both people and goods with wide concrete aprons, well-maintained roads and footpaths, and ample parking spaces for passenger and commercial vehicles, always ensuring smooth operations.

CCTV cameras, human surveillance personnel and stringent visitor management systems also add an extra layer of security.

Retrofits for Energy Efficiency:
We integrated rooftop solar to power operations and have also integrated solar-powered lights throughout the park, ensuring energy-efficient illumination of roads, pathways, and common areas. This not only reduces dependency on conventional power sources but also exemplifies our focus on sustainable urban infrastructure.

Initiatives for Resource Conservation:
Water conservation, waste management, and renewable energy initiatives are seamlessly integrated into the park’s design, reinforcing our commitment to sustainability.

These initiatives include using energy-efficient retrofits such as LEDs for illumination, solar-powered streetlights and smart meters for monitoring and optimising consumption to offset the facility’s energy impact. We also have installed electric vehicle charging points to promote the use of greener transportation and emission reduction. For guests at our office, site tours are conducted using our in-house electric golfcart.

For water stewardship, we have taken measures like installing rainwater harvesting ponds, treating grey water for reuse for flushing and landscaping as well as incorporating low flow plumbing and fixtures, and smart water meters can help reduce the intake of fresh water.

Good waste management practices are encouraged by segregating all waste through colour coded bins and recycling the collected waste. Onsite compost pits can be used for processing and upcycling horticulture waste into fertiliser.

Human-Centric Design:
Chakan II is more than an industrial park; it’s a thoughtfully crafted environment designed to enhance the well-being of everyone who steps through its gates.

Employees can unwind amidst lush greenery, including an urban forest, butterfly gardens, and lily ponds. An open gym and a versatile sports arena provide opportunities for physical rejuvenation and team bonding. A creche supports working mothers in balancing their careers and personal lives. A multi-sports arena encourages people to indulge sports regularly.

Our facilities go above and beyond to ensure the safety and comfort of all occupants. We conduct regular health checkup sessions for the tenant employees. There is also a 24×7 ambulance and onsite first-aid station provide immediate medical assistance when needed.

Recreation and Engagement:
Horizon’s vibrant social ecosystem is designed to bring people together through meaningful interactions and shared experiences. Events like Agility Day and friendly cricket tournaments are hosted regularly, offering tenants and their teams a chance to unwind, bond, and collaborate outside the workplace. Coupled with festival celebrations and community-building activities, these recreational initiatives strengthen relationships and promote a sense of camaraderie, ensuring the park thrives as both a professional and social community.

Sustainability at the Core:
Environmental responsibility is a cornerstone of our operations at Chakan II, and every feature is a testament to our dedication to a greener future.

The park is IGBC-certified and rated Platinum owing to its stringent compliance with global green building standards. Rooftop solar installations with a capacity of 3.9 MW reduce carbon emissions by over 421 tonnes annually, equivalent to planting 19,130 trees.

Throughout the park, we have developed multiple landscape pockets that boost the biodiversity of the area, with 6,000 new trees planted across the park in and around the urban forest, open gym, multi-purpose sports turf, lotus pond and the butterfly garden, in collaboration with the park tenants.

At Horizon Industrial Parks, health and safety take centre stage as key components of our ESG commitment. Regular health camps, cleanliness drives, safety awareness drives and emergency response training sessions are organised to ensure the well-being of everyone within the park. These initiatives go beyond compliance, fostering a culture where safety and health are intrinsic values.

Proactive Collaboration and Commitment to Excellence:
Beyond infrastructural upgrades, we have a robust feedback mechanism in place to record, review and maintain the needs of tenants at every park, including Chakan. We undertake regular testing, third-party auditing and preventive care and maintenance activities to ensure that our customers enjoy uninterrupted operational uptime.

One of our customers at Chakan II, Jaideep Redkar, President Global Supply Chain, Prose Technologies, has shared, “Our relationship with Horizon Industrial Parks started in 2018 when we were on the lookout for a manufacturing space in Pune. What we find good about Horizon is they are the perfect partner in terms of constructing the space we wanted, in the way we wanted, in record time. From the time we have come here [at Chakan], everybody has been impressed with the facility that we have created. We consider this facility in India as one of our top facilities globally.”

Another customer, Mukund Gangane, Chief Executive Office, Benteler Automotive India, has noted, “The review mechanism of Horizon Industrial Parks is noteworthy. It is not a formality; it is a proactive approach with a highly collaborative effort. This ensures that we are on the right path of continuous improvement. This approach is noticeable through every aspect of our partnership, whether it is refining operational processes, advancing sustainability initiatives, enhancing safety protocols or engaging in sports and social activities.”

Empowering Communities
At Horizon, our impact extends beyond the industrial park, reaching into the communities around us.

Job Creation: Employing over 3,000 individuals, with 23% being women from nearby areas, the park contributes positively to economic growth and gender diversity.

Social Initiatives: Through a structured recycling drive, plastic waste generated within the park was collected, segregated, and sent to be recycled. The recycled plastic was used to create 19 sturdy benches, designed to meet the daily needs of students in local schools. These benches were donated to classrooms, enhancing the learning environment and providing students with much-needed infrastructure for comfort and productivity.

Conclusion
Our clients consistently commend Chakan II as one of the premier industrial and warehousing parks in the region. Their testimonials reflect the quality of our facilities and the strength of our partnerships.

The strategic upgrades at Horizon Industrial Park Chakan II, with a strong commitment to sustainability, enhanced operational efficiency, and future-ready infrastructure, position this logistics park as an ideal choice for tenants seeking growth and innovation in a sustainable environment. These improvements not only streamline operations but also prepare the facility for future challenges and opportunities, aligning with Horizon’s mission of delivering superior quality infrastructure. Furthermore, the park’s strategic positioning for growth emphasises its readiness to support the accelerated success of its tenants, making it a benchmark in the industrial and warehousing in India.