● 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-Compliant & 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-compliant 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.