Case Study Jaquar

The Client

The Jaquar Group, founded in 1960, is one of India's largest and most recognised manufacturers of complete bathroom and lighting solutions. Headquartered in Manesar, Haryana, Jaquar operates multiple state-of-the-art manufacturing facilities across India and South Korea, spread over more than 3,30,000 sq. m. The company produces over 52 million bath fittings, 4.8 million sanitaryware pieces and 28 million lighting products annually, serving customers in more than 55 countries. Jaquar has been recognised as India's most trusted bath fittings brand and continues to expand its manufacturing footprint to meet growing domestic and global demand.

The Need

As Jaquar scaled up production capacity at one of its manufacturing facilities, a critical operational challenge emerged: the efficient vertical movement of heavy materials — including raw materials, semi-finished components and finished bath fittings — between the ground floor and upper production levels.

The existing process relied heavily on manual handling and conventional lifting methods, which presented several problems:

• Slow material transfer between floors, creating bottlenecks in the production workflow.
• High dependence on manual labour for lifting and shifting heavy components, leading to fatigue and reduced worker productivity.
• Safety risks associated with manually moving heavy loads across floor levels in a busy manufacturing environment.
• Production delays caused by inconsistent material availability on the upper production floors.
• Limited load capacity of existing equipment, which could not keep pace with the increasing throughput demands of the expanding facility.

Jaquar required a robust, large-platform vertical lifting system that could handle heavy loads reliably, integrate with the plant's production workflow and operate safely in a high-throughput manufacturing environment.

The Solution

The Bricspac team visited the Jaquar manufacturing facility, met with the plant operations team and conducted a thorough site assessment to understand the material flow, load requirements and floor-level configurations. After evaluating all aspects of the challenge, Bricspac proposed the design and installation of a custom-engineered, large-platform Vertical Reciprocating Conveyor (VRC) — purpose-built to handle the vertical movement of heavy materials between production floors.

The scope of work included:

• Custom structural fabrication — Heavy-duty blue mild steel structural frames with cross-braced supports were fabricated and assembled on-site to form the VRC's load-bearing framework. The structure was engineered to withstand the weight and frequency demands of continuous industrial operation.
• Large-platform VRC installation — A wide-area lifting platform was installed, designed to accommodate heavy and bulky loads such as pallets, crates and production components. The platform features sectioned ribs for load stability during vertical transit.
• Mezzanine-level integration — The VRC was integrated with the facility's mezzanine and upper-floor production areas, with yellow safety railings, access gates and landing zones configured for safe loading and unloading at each level.
• Hydraulic drive system — A hydraulic power pack was installed to deliver smooth, controlled vertical movement with consistent speed and positioning accuracy.
• Operational controls — Signal indicator lights (red, green, blue) and push-button controls were installed for safe operation, enabling floor-level communication between operators during loading and unloading cycles.
• Crane-assisted installation — Given the scale of the equipment, a mobile crane was deployed inside the facility to position and assemble the heavy structural components and drive system during the installation phase.

The entire project — from structural fabrication and assembly to commissioning and operator training — was executed on-site within the agreed timeline.

The Results

Following the installation and commissioning of the VRC, the Jaquar plant operations team reported significant improvements across multiple areas:

• Faster material movement between production floors, reducing waiting time and improving production flow continuity.
• Reduced manual handling of heavy loads, lowering the risk of worker fatigue and on-floor injuries.
• Higher throughput capacity — the large-platform VRC handles heavier and bulkier loads than the previous system, matching the facility's increased production demands.
• Improved workplace safety with dedicated safety railings, access gates and signal-light communication between floors.
• Consistent, reliable operation with minimal downtime, supporting continuous manufacturing schedules.

Bricspac continues to provide ongoing maintenance support and service for the VRC installation, ensuring reliable long-term performance at the Jaquar facility.