January 10, 2024

Elion – Uncovering Hidden Threats and Optimizing Efficiency in a Maharashtra Warehouse with Thermography


Elion Technologies & Consulting Pvt Ltd is proud to showcase its commitment to proactive risk mitigation and operational excellence through a recent project at a large-scale warehouse in Maharashtra. This case study highlights the effectiveness of Thermography in detecting hidden electrical and mechanical issues within critical warehouse equipment, preventing potential downtime and damage, and ultimately optimizing efficiency and ensuring safety for the facility.

Project Overview:

Our client, a leading logistics provider in Maharashtra, recognized the crucial role of reliable equipment and efficient operations in maintaining uninterrupted inventory movement and maximizing storage capacity. Aware of the limitations of traditional maintenance methods, they engaged Elion Technologies to conduct a comprehensive thermography audit, seeking to uncover unseen problems and optimize their warehouse operations.

Thermography Audit Services


  • Our certified thermographers utilized advanced thermal imaging cameras to capture temperature variations across all critical warehouse equipment, including:
    • Forklifts and pallet movers.
    • Conveyor belts and sorting systems.
    • Electrical panels and distribution systems.
    • Refrigeration units and cooling systems.
  • Detailed infrared images revealed subtle temperature differences, indicating potential problems invisible to the naked eye.
  • Our experts analyzed the data, compared it to established benchmarks, and identified areas requiring further investigation or immediate intervention.

Unveiling Hidden Dangers and Inefficiencies:

The thermography audit revealed several crucial findings:

  • Overheating components: Certain forklift engines, conveyor belt motors, and electrical connections exhibited elevated temperatures, exceeding safe operating limits and posing a risk of equipment failure, accidents, and even fires.
  • Inefficient cooling systems: Uneven air distribution and clogged filters compromised the effectiveness of refrigeration units, potentially leading to product spoilage and energy waste.
  • Faulty electrical connections: Loose or overloaded connections generated excessive heat, increasing the risk of electrical fires and potential damage to sensitive equipment.
  • Lubrication inconsistencies: Uneven or insufficient lubrication on certain moving parts resulted in increased friction and heat generation, accelerating wear and tear.

Immediate Action and Preventive Measures:

Based on these findings, we:

  • Promptly alerted the client to the overheating equipment and advised immediate shutdown for repairs or replacements, potentially averting breakdowns and costly downtime.
  • Recommended targeted maintenance of refrigeration units, including cleaning filters, optimizing airflow, and adjusting cooling settings.
  • Suggested repairs or replacements for faulty electrical connections to eliminate fire risks and ensure stable power supply for equipment.
  • Advised adjustments to lubrication schedules and procedures to address uneven wear and tear on moving parts.


By diligently implementing our recommendations, the Maharashtra warehouse achieved remarkable results:

  • Prevented Downtime and Damage: Timely intervention on overheating equipment prevented potential failures and damage, safeguarding valuable inventory and ensuring uninterrupted operations.
  • Reduced Energy Costs: Improved cooling system efficiency and optimized electrical connections minimized energy consumption, lowering operational costs.
  • Enhanced Safety: Addressing faulty electrical connections and optimizing lubrication practices reduced fire risks and created a safer environment for workers and equipment.
  • Increased Operational Efficiency: By minimizing downtime and improving equipment performance, the warehouse maximized storage capacity and boosted overall operational efficiency.


This case study exemplifies the power of Elion Technologies’ thermography expertise in safeguarding critical warehouse infrastructure and optimizing operations. By identifying hidden threats before they escalate, we helped this Maharashtra warehouse not only prevent disruptions and damage but also enhance safety, efficiency, and profitability for their logistics business.

Elion Technologies & Consulting Pvt Ltd is your trusted partner for ensuring the reliability, efficiency, and safety of your critical warehouse equipment. We offer a wide range of services, from thermography audits and predictive maintenance to electrical safety audits and energy management solutions.

Contact us today to protect your inventory, your equipment, and your business continuity.