Strategic Xpress® Integration Transforms Energy Consumption at Major Tire Plant

Strategic Xpress® Integration Transforms Energy Consumption at Major Tire Plant

$154,000

1,544,000

location

LaVergne, TN

size

1,200 tons capacity

industry

Rubber & Tire

the problem

Inefficient Cooling in High-Output Production

The Tennessee facility faced significant energy inefficiencies in their cooling systems. The site, which produces truck and bus tires with an output of 7 million annual ton hours, operated 24/7 with extremely limited maintenance windows, making traditional system replacements impractical. The existing cooling infrastructure had several critical inefficiencies:

  • A constant flow hydronic design with static chilled water supply temperature setpoint year-round
  • Excessive pump power consumption for both condenser water and process chilled water
  • High energy consumption relative to cooling output, resulting in unnecessary operational costs

the solution

Seamless Integration with Zero Downtime

Looking to maximize efficiency without disrupting operations, the facility partnered with a recognized leader in HVAC optimization technologies. Xpress® is an intelligent optimization system that dynamically adjusts cooling parameters in real-time, designed specifically for energy-intensive industrial environments where production continuity is critical.

The implementation strategy prioritized both energy savings and operational stability:

  • Xpress® technology was seamlessly integrated with the existing Schneider building automation system to ensure maximum cooling efficiency in real-time, maintaining all process requirements at the lowest possible kW/ton
  • All existing equipment remained in place, eliminating production downtime
  • The standard Xpress® package included an Energy Efficiency Performance Dashboard, eliminating the need for separate monitoring system investments. This system provides real-time monitoring of system performance, including kW and kW/ton metrics for each major equipment piece and the total chilled water system

We maintained 100% uptime throughout the integration while securing immediate financial benefits.

Plant Manager

the results

Cost Savings and Performance Excellence

The implementation yielded impressive returns that validated the strategic investment in energy optimization:

  • Optimized cooling efficiency using existing equipment
  • Annual energy costs reduced by $93,000
  • 1,544,000 kWh saved annually
  • $154,000 TVA utility rebate secured
  • 3-year project payback period
  • Real-time performance monitoring via the Energy Efficiency Dashboard
  • Zero production disruption during implementation

The Xpress® solution demonstrates how targeted optimization of existing systems can deliver substantial energy and cost savings while maintaining critical manufacturing operations.

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