High efficient FRP cooling tower fan
The Cooling tower is a type of heat exchanger it transfers process waste heat to the atmosphere. Circulating water used to reject heat by the airflow generated by the cooling tower fan.
At Maya, we manufacture a broad range of FRP cooling tower fans. These fans are energy-efficient and achieve up to 40% power saving.
The cooling tower fan is key-equipment in the tower. It must have the following properties-
- High Performance: Cooling tower fan must deliver high performance in its full lifetime.
- Reliability: Entire process in the plants depend on the cooling tower. So in the case of CT fan failure, plant operation stops. Thus cooling tower fan must have the highest reliability.
- Fan Constructions: Cooling tower fans must have robust construction as it has to run 24 hr 365 days.
- Fan Efficiency: These cooling tower fans are high energy consumption equipment. So to save energy, the fan must have the highest-efficiency.
We know the operating environment of the cooling tower fan is full of corrosion. It proves fibre-reinforced plastic “FRP” as the best material for cooling tower fans. FRP is light in weight and high in strength as well as it is having excellent resistance to corrosion. So it must be a primary focus to use FRP fan for high efficiency.
🌟 Why Choose FRP Cooling Tower Fans?
Fiberglass-Reinforced Plastic (FRP) fans offer exceptional advantages over traditional metal fans. Engineered from advanced resin-fiber composites, FRP blades deliver 3 Key Features for Energy Savings :
Superior corrosion resistance, ideal for humid, coastal, or chemically aggressive environments.
Lightweight yet structurally robust construction — easier to handle and install while reducing stress on motors, gearboxes, and bearings.
Longer durability, with blades that resist dents, warping, metal fatigue, and joint failures better than aluminum alternatives.
Specification of our cooling tower fan
%
Up to 40% power saving in CT fan
Fan Diameter range in foot
Airflow range Up To
%
Number Of Blades Up to
RPM range up to
Static Pressure in mm of wg
🌟 FRP Cooling Tower Fans: Features, Benefits & ROI
⚡ Exceptional Energy Efficiency & Cost Savings
Maya’s FRP Cooling Tower Fans deliver up to 30–40% energy savings compared to conventional aluminum or metal fans, supporting India’s industrial energy efficiency initiatives and helping industries reduce their carbon footprint while achieving significant cost savings through:
Optimized aerodynamic design with hollow aerofoil blades that reduce air resistance and enhance airflow.
Computer-balanced impellers for efficient operation, minimizing energy losses, vibration, and noise.
Adjustable blade pitch for on-site fine-tuning, maximizing performance and reducing power consumption.
Significant reduction in electricity bills and a lower carbon footprint, supporting sustainable plant operations.
🔇 Quiet & Smooth Operation
Our FRP fan blades are engineered for low noise emissions and whisper-quiet running:
Hollow aerofoil profiles minimize turbulence and aerodynamic noise.
Precision dynamic and static balancing reduces vibration, protecting gearboxes, shafts, and bearings while ensuring a smooth, silent airflow.
Ideal for industrial sites that require environmental and worker safety compliance through low noise levels.
🛡️ Superior Corrosion Resistance & Durability
Built from high-grade Fiberglass Reinforced Plastic (FRP), these fans thrive in harsh, corrosive environments:
Withstand exposure to acid fumes, salts, humidity, and coastal climates without rusting or metal fatigue.
Non-metallic design eliminates galvanic corrosion and the need for additional surface treatments or coatings.
Single-piece molded blades remove weak points like joints, extending operational life to 15–25 years with minimal maintenance.
🛠️ Low Maintenance & High Reliability
Our fans are designed for easy upkeep and long-term reliability:
Low vibration operation protects connected equipment, reducing wear on gearboxes, bearings, and shafts.
Minimal maintenance demands: no rust control, fewer replacements, and easy cleaning routines.
Field-serviceable with an adjustable pitch for performance tuning without complex disassembly.
💰 Rapid Payback & Long-Term ROI
Investing in Maya FRP Cooling Tower Fans means:
Payback in 3–8 months through substantial energy savings and reduced maintenance costs.
Lower total cost of ownership (TCO) than traditional aluminum or galvanized steel fans.
Proven reliability trusted by leading power plants, process industries, and cooling tower OEMs worldwide.
✅ Why Choose Maya FRP Cooling Tower Fans?
Combining advanced aerodynamic design, corrosion resistance, low noise, and unmatched durability, Maya’s FRP Cooling Tower Fans deliver the best long-term performance and value for industrial cooling applications. Upgrade today and benefit from sustainable energy savings, reduced maintenance, and dependable cooling for years to come.
Power saving opportunity with FRP cooling tower fans
In power plant cooling tower fans are among the highest energy consumption equipment so even a small saving in fan power is an achievement.
The fan is a cooling tower part that is easiest and cheapest to modify and having a high impact on the performance.
- Power Saving Against metallic fan is up to 40%
- Saving against conventional FRP fans is up to 25%
- And saving against our own fan installed before 2015 is up to 20%
Payback period is as low as 8-3 month
Zero cost solution
✅ Technical Snapshot
- Fan Type: Axial, induced/forced draft
- Blade Design: Hollow aerofoil profile for high efficiency
- Material: Fiberglass Reinforced Plastic (FRP)
- Balancing: Computer-controlled static & dynamic balancing
- Energy Efficiency: 15–40% lower energy consumption compared to metallic fans
- Noise & Vibration: Low noise due to aerodynamic design and minimal vibration
- Corrosion Resistance: Excellent performance in saline, humid, or chemical-laden air
- Lifespan: 15–25 years with minimal maintenance
- Blade Count: Customizable based on fan diameter and airflow requirement
- Pitch Adjustment: Field-adjustable for optimum performance
- Diameter Range: Typically 600 mm to 3200 mm or more
- ROI: Typical payback period between 3 to 8 months
Why FRP Cooling Tower Fans Are Superior
Fiberglass-Reinforced Plastic (FRP) fans offer unmatched advantages for cooling towers, especially in corrosive or humid environments. These fans are engineered from resin-fiber composites that resist rust and degradation far better than aluminum or steel
Energy-efficient design cuts power requirements by 25–40%, thanks to aerodynamic blade profiles and computer-balanced impellers. Adjustable pitch settings allow on-site tuning for optimal airflow and performance .
Their hollow aerofoil blades also significantly reduce noise and vibration, while dynamic/static balancing ensures stable, quiet operation .
Maintenance demands are low—with molded single-piece blades minimizing weak points and corrosion requiring no coatings. These fans can last 15–25 years, making them a long-term asset
Despite a modestly higher upfront cost, ROI is fast—typically 3–8 months, courtesy of reduced energy use and minimal upkeep .
Cooling Tower Fan Key Feature
High Efficient FRP fan impeller.
Low Operating Costs.
Up to 40% power saving against conventional fans.
Long Life fan Construction.
Zero Downtime with minimum care.
Fast emergency response.
Very low payback period in case of replacement of existing fan.
Hollow blade construction Reduce fan weight and increase life of mechanical components.
Zero Cost Solution for power saving opportunity.
Why choose Maya Cooling Tower fan?
Low Operating Costs
- Maya High efficient airfoil blade design
- Optimization of twist cord and cross-section provide high efficiency.
- The involvement of the most advanced composite material. Reduces turbulence and produces smooth linear airflow.
- Best design for the duty point No over-sizing of the fan.
- High ratio of the coefficient of lift to the coefficient of drag.
Efficiency and performance
- The aerodynamic hub provided with a fan.
- It functions like an airplane nose.
- High airflow delivery due to zero re-circulation.
- The fan surface is mirror finish it delivers laminar flow over the blade length.
- The option is available for high to very high-pressure fans.
- Less power consumption to deliver the same airflow.
- Low payback period in case of replacement of existing fan.
- High performance in all weather and environment.
- Zero Cost Solution for power saving opportunity.
Long Life Construction
- Most of the parts made of Heavy-duty composite and hot-dip galvanized material. It meets the corrosion resistance and equipment life requirements of heavy industrial applications. While still delivering an outstanding value.
- A lightweight impeller, thus, increases the life of all the mechanical components.
- Cooling tower Fans are also available with Series 300 stainless steel. It is an optional upgrade that comes with a 5-year limited warranty.
- Maya cooling tower Fans manufactured in ISO-2015 certified facilities. It attests to our commitment to comprehensive quality processes and systems that meet international quality management standards.
Fast emergency response.
- Ready-made fan available.
- The minimum stock of the fan spare maintained.
- Low manufacturing time because of zero outsourcing.
- An expert team available for fan installation.
Quiet by Design
- The composite blade has a glossy surface finish that offers smooth airflow.
- low tip speed design (Noise is directly proportioned to tip speed).
- No outsourcing full quality control thus achieves the least tip clearance.
- Special design available for extra low noise fan which can reduce noise up to 10 dba compares to conventional fans.
Performance for All Seasons
The fan is a constant flow machine. To maintain its performance, despite critical variation in weather our fans designed for a broad range of operations. Our fans are having a good amount of reserve margin for both airflow and static pressure. Thus fan performs throughout the year in all types of seasons.
Low Maintenance/Less Downtime
- Maya FRP cooling tower fans made of high-quality material and robust design.
- Maya design fan for low operating tip speed, it increases system life and also reduces the chance of failure.
- Unlike the painted fan, we do provide a permanent coating of a gel coat that remains an integral part of the fan blade body. And it does not get separated due to erosion.
Quality and construction
- Hollow blade construction Reduces fan weight which reduces starting torque.
- Lightweight FRP blade increased life of mechanical component i.e. cooling tower fan gearbox, driveshaft, motor, and bearings.
- Excellent corrosion resistance with consistent performance even after a long time of operation.
- Cooling tower fan assembly is statically balanced as per ISO 1940 grade 6.3 or 2.5 if required.
- Small fans of up to 10 feet diameter are dynamically balanced.
- The fan has reduced vibration due to closed-circuit operation.
- Long life of fan due to reduced vibration and fatigue.
- Low noise operation due to laminar flow and less vibration.
- Updated fan manufacturing Facility and no outsourcing thus better control on quality.
- The latest technologies used to improve the product and manufacturing process of fans.
- The option is available for low to very low-noise cooling tower fans, with a blade of up to 1.2-meter chord width.
We serve all 3 main categories of Mechanical draft cooling tower:
- Forced draft cooling tower fan.
- Induced draft crosses flow cooling tower fan.
- Induced draft counter flow cooling tower fan.
The cooling tower is also categorized by its construction–
- FRP Cooling towers
- Timber cooling towers
- Concrete cooling tower
- Latest introduction Pultrusion cooling tower.
Maya Fan installation is there in each type of cooling tower in the list.
We are India’s largest fan supplier to the cooling tower manufacturer (OEM).
All the major cooling tower maintenance and repair companies are our associates.
With our expertise in axial fan blade design, we develop more than 100 customized fans.
We have a proven track record for power saving in metallic cooling tower fans as well as in conventional FRP cooling tower fans.
Maya FRP cooling tower fan construction
Here is the list of Maya cooling tower fan components with a there brief detailing
Cooling Tower Fan Blade
Maya cooling tower fan blade made of latest airfoil similar to an airplane wing. We do select the most advanced airfoil possible for the fan to provide maximum efficiency. Due to this, we achieved superior performance. Our blade is robust in construction and designed for 7-10 times of operating load. We also provide superior wear resistance material to maintain surface stability for a long period of time. This prevents efficiency deterioration over a period of time.
This FRP cooling tower fan blade is having some very charismatic properties. It is very much possible to produce any complicated shape with ease. Thus provide an economical solution.
some of its special features are listed below –
- Our cooling tower fan blade uses high-grade fiber reinforced plastic (FRP).
- Single-piece Joint-less molded and Pultruded FRP blades with E glass fiber and epoxy resin.
- High strength at low weight.
- Good impact, fatigue, and Tensile Strength (Ultimate)
- Excellent environmental resistance.
- The anti-static fiber used for blade manufacturing.
- High-quality UV protection to achieve a long life of the blade.
- Excellent chemical and corrosion resistance.
- Superior surface finish.
- The blades having hollow construction to reduce the weight.
- The aerodynamic profile in its full blade length. (unlike conventional blade having up to 30 % blank area)
- Better life of the entire cooling tower fan system due to low assembly weight.
- Excellent twist to width combination achieve high-efficiency.
- All the blades made with core for high load capacity.
- A combination of various fibers used to achieve superior strength.
- The blade is broad at the shank and reduced toward the tip. It maintains the constant air velocity throughout the length.
- Low moment of inertia help for the selection of optimum motor and reduce over design due to higher starting torque thus motor operate under a better range of efficiency.
- Blades overlap to the aerodynamic hub. It closes the circuit to block the reverse movement of air.
- Many blade designs are available for different duty points. Each blade design helps to achieve high efficiency at a specific application.
Maya FRP cooling tower fan blade Advance feature
- All our cooling tower fan blades having leading-edge protection to avoid erosion.
- The option is available for stainless steel leading edge.
- Blades tested for structural stability.
- Fan blades can have FR material if required.
- Replaceable leading edge. (Where leading-edge damaged due to faulty cooling tower drift eliminator.)
- Blades use anti-static fiber to prevent static charging.
- Full proof structural design of blade that passes 4 times load test.
- Blades tested for the proof load.
- The blade is moment balance so that it can replace when required.
- Blades tested for track variation.
Every new blade design tested under an in-house wind tunnel. - A full evaluation of fan performed before launch.
Fan Hub / Boss
Hub used in cooling tower fans is heavy in construction. In this, we are using a heavy thickness mild steel plate, cast iron or Aluminum clamp, and stainless steel hardware. It provides long life, as we coat all mild-steel parts with a heavy thickness of zinc. Note – Optionally we also customize hub/Boss on demand of the customer, like caste hub boss, Spider Type Fabricated hub, etc.
Key Feature
- Heavy-duty MS fabricated.
- Hub is dynamically balanced as per ISO 1940 grade 6.3 or 2.5 if required.
- The individual part of the hub is moment balanced.
- All the MS parts are hot-dip galvanized Option for different grades of ss plate is also available.
- FE – 200 cast iron block or Aluminum block.
- FE – 200 cast iron central bush.
- Hardware SS163, SS304.
- Nut bolt used is of coated HT or stainless steel series.
- For sea weather application Solvent Free, Self-levelling Coatings are available.
Taper Locking
In most of our cooling tower fans, we preferred to have a taper locking arrangement. It is a proven part of the easy assembly in the field. These taper lockings made of Cast iron or stainless steel.
AERODYNAMIC HUB
is made of E-glass anti-static fiber, having UV protection, it is available in the segment for ease of transportation.
- This hub maintains laminar airflow at the center of the fan and avoids eddies generation.
- It has a high surface finish for smooth airflow.
- Anti-static properties to avoid the static charge.
- Seals the fan circuit and avoids air recirculation.
- With the use of an aerodynamic hub, The designer gets the freedom to reduce the mechanical hub dimension.
Unlock All Feature Of Cooling Tower Fan With Our Special Feature Presentation
FEW OF OUR PRESTIGIOUS COOLING TOWER FANS CUSTOMER
❓ Frequently Asked Questions – FRP Cooling Tower Fans
What are the advantages of FRP over aluminum fans?
FRP fans offer better corrosion resistance, lower weight, reduced noise, and longer lifespan compared to aluminum fans.
How much energy can I save by using FRP cooling tower fans?
You can save up to 40% power over metallic fans and up to 25% over conventional FRP fans.
Are these fans suitable for coastal or chemical environments?
Yes, FRP construction makes them highly suitable for humid, saline, or chemically aggressive locations.
What is the expected lifespan of an FRP cooling tower fan?
Typically 15–25 years depending on operational conditions and maintenance.
What is the function of a cooling tower fan?
A cooling tower fan increases airflow through the cooling tower to enhance the evaporation process. By moving large volumes of air across the fill media, the fan accelerates heat dissipation and improves the tower’s overall cooling efficiency.
How does blade design affect the performance of a cooling tower fan?
Blade design influences airflow, energy efficiency, and noise levels. Aerodynamically designed blades ensure smooth air movement with minimal resistance, reducing power consumption and increasing overall performance in cooling applications.
What are the benefits of using lightweight fan blades?
Lightweight fan blades reduce the load on the motor, enabling smoother operation, lower energy consumption, and extended equipment life. They also help minimize vibrations and mechanical wear during continuous operation.
Can cooling tower fans be customized for specific requirements?
Yes, fans can be customized in terms of diameter, number of blades, pitch angle, and hub design. Customization ensures optimal performance based on cooling load, structural design, and environmental conditions.
How does variable fan pitch improve efficiency?
Adjustable fan pitch allows operators to fine-tune airflow according to system demand. This flexibility helps maintain consistent cooling performance while minimizing energy use, especially during seasonal load variations.
What maintenance is required for cooling tower fans?
Routine maintenance includes inspecting blade integrity, tightening hardware, checking for balance and alignment, lubricating bearings (if applicable), and monitoring vibration levels. Preventive care ensures safe, long-lasting operation.
How can cooling tower fan noise be reduced?
Noise reduction can be achieved by using optimized blade profiles, installing sound-dampening components, operating at lower RPMs with VFDs, and ensuring regular maintenance to prevent mechanical imbalance or wear.
Are modern cooling tower fans energy-efficient?
Yes, modern fan systems are designed with energy efficiency in mind. With advanced blade designs and optional VFD integration, they provide high airflow at reduced power consumption, helping lower operational costs.
What factors should be considered when selecting a cooling tower fan?
Key selection factors include air volume requirement, static pressure, noise level, material compatibility, blade design, operating environment, and energy efficiency. Proper selection ensures performance and reliability.
What standards or certifications are relevant to cooling tower fans?
Reputable fans comply with industry standards such as AMCA (for air performance and sound certification), ISO 5801 (performance testing), and CTI guidelines (for thermal performance and durability in cooling towers).
Few important calculations of “Cooling Tower Fans”
Fan Law Calculation For Cooling Tower Fan
Cooling Tower Fan CTI Point Calculation :
Cooling Tower Fan Airflow Calculation :
Cooling Tower Fan Shaft Power Calculation :
Cooling Tower Fan Velocity Pressure - By wind speed Input :
Cooling Tower Fan Velocity Pressure - By Airflow Input
Cooling Tower Fans Pay Back Period Calculation: