When it comes to solving tough industrial problems, the team at Lee Company knows how to deliver. A recent project presented an all-too-familiar challenge – dirty process water and inefficient systems that were impacting production. Our client, an automotive parts manufacturer, needed a solution fast, and we were ready to take on the challenge.

The Challenge

The client’s manufacturing process for automotive interiors and exteriors generates significant heat, demanding a cooling system that works efficiently around the clock. However, their existing chill water system wasn’t up to the task – it was outdated and inefficient. Worse still, the site was dealing with flow issues due to improper pipe sizing and routing. The system was mismatched, inefficient, and simply couldn’t keep up with the demands of modern manufacturing.

The Solution: Flexibility and Efficiency

Lee Company stepped in to replace the entire system, from the pumps to the heat exchangers and piping. Instead of the previous mix-and-match setup, we provided a single, unified piping system that not only improved efficiency but also paved the way for future growth. Flexibility was a key consideration in the new design. We included connections for future expansion, ensuring that as the plant’s needs change, the system can easily adapt.

And it didn’t stop there. We reused an existing onsite chiller that still had capacity, saving the client a substantial amount of money. By incorporating variable frequency drives (VFDs) on the pumps, the system could now adjust its flow to meet demand, minimizing energy usage and cutting costs.

Christmas Deadline? No Problem!

Timing was critical for this project. With the plant scheduled to shut down for Christmas, our team had just two weeks to replace the entire system. We didn’t just meet the deadline – we exceeded expectations. In that short window, we tore out the old system, installed the new one, and ensured everything was running perfectly. We even created a detailed operations manual, leaving the client with a user-friendly guide for future reference.

Built to Last, Designed for Efficiency

At the heart of this project was Lee Company’s dedication to efficiency and future-proof design. The new system operates with an impressive level of flexibility and balance, ensuring it will never overload. With built-in redundancy for pumps, chillers, and other key components, the plant is protected from potential failures. This was not just about solving an immediate problem – it was about creating a solution that will stand the test of time.

An All-Hands-On-Deck Approach

From the fab shop to the field, this project showcased the best of Lee Company’s expertise and teamwork. Every department worked together to deliver a seamless, turnkey solution, making this one of the largest pre-packaged skids we’ve ever built. The skid, built offsite for safety and efficiency, was insulated, wired, and tested before being transported to the plant. Once on-site, it was simply connected and ready to go.

The Results: Maximum Efficiency, Minimum Effort

Thanks to smart design and careful planning, the new system delivers on every front – efficiency, flexibility, and cost savings. By using existing assets and designing for future adaptability, Lee Company provided a solution that not only solved the client’s immediate needs but also positioned them for future success.