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From stifling to streamlined: a scalable cooling solution for peak productivity

Client: Automotive parts manufacturer

Location: Tennessee

Sectors: Manufacturing

The Challenge

Heat, humidity, and high turnover threaten production

An automotive parts manufacturer struggled with extreme heat in its 250,000 sq. ft. facility—an industrial space retrofitted from a storage warehouse. The lack of infrastructure for temperature control led to unbearable working conditions, high employee turnover, and decreased production rates during summer.

With no available CAPEX for HVAC upgrades, the company faced compliance risks, reduced workforce efficiency, and potential quality issues such as rust, curing delays, and mold due to excess humidity. The plant needed a cost-effective, scalable solution to maintain production levels and protect workers and products.

Key Facts

Ambient temperatures inside the facility, impacting worker safety and production. 90°F+
Cooling solution is deployed annually to maintain optimal conditions. 6 month
Partnership ensuring year-round production efficiency without CAPEX investment. 3+ year

The Solution

A custom cooling system for a tough environment

Aggreko’s engineering team conducted an on-site assessment to evaluate the facility’s unique challenges, including space constraints and the need for a scalable solution. Recognizing these factors, the team designed a tailored cooling strategy that seamlessly integrated into existing operations.

The customized solution included a cooling package comprised of a chiller with strategically placed air handling units to optimize airflow and efficiency while leveraging available power infrastructure.

By implementing a repeatable, seasonal approach, the manufacturer maintained optimal working conditions without needing permanent infrastructure—ensuring reliable performance and cost efficiency. In its third consecutive year, this solution has become a critical component of the plant’s annual operations.

The Impact

Cooler temperatures, higher productivity, and ongoing partnership

With Aggreko’s cooling solution, the facility saw:

  • Winter-like production levels are maintained year-round.
  • Improved worker retention and morale, reducing turnover.
  • Elimination of heat-related product defects and delays.

This successful annual deployment has evolved into a long-term partnership, ensuring the plant remains operational and efficient—without the burden of capital expenditures.

Before

  • 90°F+ indoor temperatures affecting worker safety and product quality.
  • Production slowed significantly in peak summer months.
  • High employee turnover due to extreme working conditions.

After

  • Consistent temperature control, ensuring year-round productivity.
  • Reduced employee fatigue and improved job satisfaction.
  • Heat- and humidity-related defects eliminated, preserving product quality.
  • Attracts better candidates and retains them longer due to the improved work environment.