Scaling Clean-Tech Assembly: How One Air Purification Innovator Partnered with Karkhana.io to Ramp Up Production

How One Air Purification Innovator Partnered with Karkhana.io to Ramp Up Production

Pi Green Innovations is on a bold mission: to make the air cleaner by reducing particulate emissions from diesel generators and other industrial sources.

Overview

Pi Green Innovations is on a bold mission: to make the air cleaner by reducing particulate emissions from diesel generators and other industrial sources.

Their flagship product, the Carbon Cutter, is a patented retrofit emission control device designed to reduce air pollution without the need for filters or frequent maintenance. But even groundbreaking ideas can hit operational roadblocks. As demand grew for its flagship product, Pi Green faced mounting pressure to scale up production without compromising on quality or efficiency. 

That’s where Karkhana.io stepped in.

Project at a Glance

Industry:

Environmental Services

Product:

Drum Assembly of Carbon Cutter for Gensets

Services Offered

Complete sourcing and project management to ensure seamless manufacturing and scale-up production.

Capabilities Leveraged

End-to-end fabrication of the drum assembly, including precision laser cutting, CNC bending for complex geometries, shot blasting for surface preparation, and industrial-grade painting to ensure durability, corrosion resistance, and aesthetic consistency.

The Ask: Build at Scale Without Sacrificing Standards

Upliance needed a manufacturing partner who could take full ownership of the product journey:

Tight tolerance drum assembly needed precision fabrication

Supplier network couldn’t scale or ensure consistency

Surface finish issues due to DFT variation in painting

Bottlenecks during volume ramp-up

Needed a partner, not just a vendor, to co-own outcomes

The Challenge: Scaling Sustainably Without Compromise

At the heart of Pi Green’s Carbon Cutter is a drum assembly that demands precise fabrication, critical tolerance controls, and robust surface treatments. While the team had an early supplier network in place, they soon found themselves constrained by limited production capacity and inconsistent quality.

Dry Film Thickness (DFT) for painting and coating posed another challenge — with environmental performance directly tied to the quality of surface finish. Moreover, the lack of a strong supplier base made it difficult to react quickly to scale-up demands or resolve process bottlenecks. They needed not just a vendor, but a manufacturing partner who could co-own the problem.

How Karkhana.io Solved It

Karkhana.io approached the engagement not just as a supplier, but as a strategic partner. The team worked closely with Pi Green to reimagine the manufacturing workflow—right from sourcing to process optimization.

1. Strategic Vendor Development

We took full ownership of the BOM, sourcing every component—metal/plastic enclosures, thermal materials, wire harnesses, and PCB assemblies. This eliminated vendor-chasing for the client and ensured all parts arrived on time and in spec.

2. Quality Engineering at the Core

Maintaining high-dimensional accuracy and material quality was non-negotiable. Karkhana.io deployed a comprehensive quality plan that included:

  • In-house Dye Penetration Testing for weld integrity
  • Material Test Certifications for raw input traceability
  • Custom gauges and stencils to verify fabrication accuracy

3. Painting & Surface Finish Control

Industrial-grade finishing requires precise paint thickness—too thin, and protection fails; too thick, and tolerances are compromised. Karkhana.io involved painting application engineers to define and implement DFT standards, ensuring both durability and fit.

4. Unlocking Supplier Capacity

To hit volume targets, we had to remove bottlenecks. This meant:

  • Introducing process-level tracking systems
  • Collaborating with vendors to rework production layouts
  • Scheduling phased deliveries to maintain rhythm while ramping up

The Results: Scale, Speed, and Savings

2.5Ă— increase in production capacity

~0% manufacturing rejections

20% cost savings from optimized sourcing

50% reduction in overall turnaround time

increase in production capacity
0 X
manufacturing rejections
~ 0 %
cost savings from optimized sourcing
0 %
reduction in overall turnaround time
0 %

More than just numbers, the outcome was a smooth, scalable supply chain that allowed Pi Green to focus on product innovation while Karkhana.io took care of execution.

Outcome Overview

The clean tech revolution can’t happen without reliable, scalable manufacturing partners. At Karkhana.io, we’re proud to help pioneers like Pi Green Innovations take their prototypes off the lab bench and into the real world—where they can make the biggest impact.

Whether you’re building EVs, medical devices, or sustainable energy products, we’re here to help you scale confidently and responsibly.

Testimonials

Frequently Asked Questions

Lorem ipsum dolor sit amet?

Lorem ipsum dolor sit amet, consectetur adipiscing elit, sed do eiusmod tempor incididunt ut labore et dolore magna aliqua. Ut enim ad minim veniam, quis nostrud exercitation ullamco laboris nisi ut aliquip ex ea commodo consequat. Duis aute irure dolor in reprehenderit in voluptate velit esse cillum dolore eu fugiat nulla pariatur. Excepteur sint occaecat cupidatat non proident, sunt in culpa qui officia deserunt mollit anim id est laborum.

Lorem ipsum dolor sit amet, consectetur adipiscing elit, sed do eiusmod tempor incididunt ut labore et dolore magna aliqua. Ut enim ad minim veniam, quis nostrud exercitation ullamco laboris nisi ut aliquip ex ea commodo consequat. Duis aute irure dolor in reprehenderit in voluptate velit esse cillum dolore eu fugiat nulla pariatur. Excepteur sint occaecat cupidatat non proident, sunt in culpa qui officia deserunt mollit anim id est laborum.

Lorem ipsum dolor sit amet, consectetur adipiscing elit, sed do eiusmod tempor incididunt ut labore et dolore magna aliqua. Ut enim ad minim veniam, quis nostrud exercitation ullamco laboris nisi ut aliquip ex ea commodo consequat. Duis aute irure dolor in reprehenderit in voluptate velit esse cillum dolore eu fugiat nulla pariatur. Excepteur sint occaecat cupidatat non proident, sunt in culpa qui officia deserunt mollit anim id est laborum.

Reach out to us!

Have questions or want to collaborate? We’re here to help!
If you’ve got an inspiring case study, we’d love to hear your story.
Reach out to publish your experience and showcase your impact.
Together, let’s highlight what innovation looks like in action.

Do you want to publish your Case Study?

Related case studies

Scroll to Top