Mercury Marine’s Award-Winning Cooling System Recirculation Piping

Mercury Marine’s Award-Winning Cooling System Recirculation Piping

by | Jan 30, 2021 | Projects

Rohde Brothers, Inc. played a pivotal role in an extensive and innovative upgrade of the central recirculated cooling water system at Mercury Marine’s die casting plant. This complex project, which won the AGC’s Build Wisconsin Award in 2021, showcases our expertise in engineering and mechanical systems integration.

Recirculation PipingThe Challenge: Mercury Marine’s growth necessitated a critical upgrade of their aging cooling system. The original system, expanded over decades, needed modernization to accommodate changes in die casting technology and to prevent operational inefficiencies and downtime.

Phased and Strategic Upgrades: Over three years, we collaborated closely with Mercury Marine to revitalize their cooling system. Our approach included:

  1. Sequential Cooling Tower Replacement: We began by replacing one cooling tower in a temporary location, ensuring no disruption to plant operations.
  2. Piping Network Overhaul: Sequential replacement of the entire network of supply and return piping was meticulously planned and executed.
  3. Optimized Water Flow Rates: Reduced flow rates led to lower energy costs and improved water quality.
  4. Final System Installation: The last phase involved relocating the cooling towers to the roof and replacing pumps and controls for the permanent setup.

Customized Solutions:

  • Replacement of cooling towers and piping in highly congested utility tunnels, requiring precise layout and review.
  • Integration of an Allen-Bradley Micrologix control system with the plant’s existing SCADA system for seamless operation.
  • Ongoing monitoring and maintenance to ensure the system’s peak efficiency and performance.

Client Testimonial: Stephen Mlinaz, Senior Facilities Engineer at Mercury Marine, commended Rohde Brothers for providing comprehensive mechanical systems integration, value engineering, and exceeding original performance expectations.

Conclusion: This project is a testament to Rohde Brothers’ ability to manage complex, large-scale industrial upgrades with precision and minimal operational disruption. Our work with Mercury Marine is a prime example of how we bring value engineering and exceptional project management to every task. If your facility is facing similar challenges, Rohde Brothers is equipped to deliver innovative solutions that exceed expectations.

Indoor Air Qualty on Your Mind?

Indoor Air Qualty on Your Mind?

by | Jan 30, 2018 | HVAC, Service

The air quality in work environments like factories, offices, and warehouses directly impacts health, productivity, and equipment longevity. Rohde Brothers, Inc. specializes in crafting air filtration systems tailored to the unique needs of different workspaces, ensuring cleaner air for a more efficient and healthy work environment.

Why Clean Air Matters: Good air quality is essential. It’s about more than comfort—it’s about health, efficient workflow, and protecting your equipment. Our job is to provide you with a solution that addresses all these needs.

Indoor Air Quality

Customized Air Filtration Strategies:

High-Efficiency Filters: We incorporate HEPA filters to trap 99.97% of minuscule particles, down to 0.3 microns. In industrial settings, we often recommend MERV-13 or higher filters for capturing even finer particles, ensuring a cleaner workspace.

Tailored Make-Up Air Units (MAUs): Our MAUs are designed to replace exhausted air with fresh, filtered air. This approach not only purifies the air but also helps maintain a balanced air pressure, reducing the ingress of unfiltered air.

Tailoring to Your Space: Each workspace has its own set of challenges, from dust and debris in factories to chemical fumes in warehouses. We design systems that address these specific challenges, considering air volume, space dimensions, and the types of pollutants present.

Direct Benefits of Our Air Filtration Systems:

  • Healthier Work Environment: Minimizing pollutants and allergens leads to a healthier team.
  • Boosted Productivity: With cleaner air, expect fewer sick days and a more vibrant, focused team.
  • Energy Efficiency: Our systems are built to be energy-conscious, reducing both environmental impact and energy costs.
  • Cost Savings in the Long Run: Protecting your machinery and HVAC systems from dust and debris means less wear and tear and lower maintenance costs.

Conclusion: Rohde Brothers is committed to transforming workspaces with air quality that supports health, productivity, and machinery longevity. Our tailored air filtration solutions are designed to meet the specific needs of your industry and space. Get in touch with us to discuss how we can enhance the air quality in your workspace.

Energy Efficient Ammonia Refrigeration – Lakeside Foods

Energy Efficient Ammonia Refrigeration – Lakeside Foods

by | Jan 30, 2018 | Uncategorized

Rohde Brothers Inc. recently completed an ambitious project for Lakeside Foods in Manitowoc, installing the refrigeration and HVAC systems for a new 138,000 square foot stand-alone freezer that operates at -10°F. This project was a showcase of precision, speed, and advanced technology.

Refrigeration pipingThe Challenge: With a highly aggressive construction schedule, there was no room for error or delays. The complexity of the mechanical systems within the building demanded meticulous coordination and innovation.

Praise from Industry Partners: Michael Bartelt, project manager for Bartelt Insulation Supply, commended Rohde Brothers for our outstanding communication, safety, and timeliness, noting our professionalism and ethical work practices as key factors in our long-term success.

Innovative Solutions:

  1. 3D Building Information and Shop Prefabrication: We maximized the use of 3D modeling and prefabrication to reduce on-site manpower needs, accelerate project delivery, and ensure seamless integration of all mechanical, plumbing, and electrical components.
  2. Advanced Control System: An Allen-Bradley programmable logic control system was used to monitor and control the entire operation, ensuring safety and energy efficiency.
  3. Shop Fabrication: We fabricated essential system components, including ductwork, piping, and control panels, in our shop for quality assurance and to maintain project momentum.
  4. Strategic Subassembly Construction: Building large subassemblies off-site ensured we could keep up with the project’s demanding schedule.

Key Installations:

  • Three 305 horsepower, 123-ton ammonia refrigeration compressors.
  • Four penthouse evaporators in the freezer area.
  • Two evaporative coolers in the dock area.
  • A 7 million BTU/hour evaporative condensing unit.
  • A 48-inch diameter, 195-inch tall high-pressure receiver.
  • Shell and tube economizer.
  • Comprehensive refrigerant pumps, heat exchangers, and accessories.
  • Condenser water pumps, tanks, and other essential accessories.
  • 2000 feet of in-floor tubing below the freezer to prevent ground freezing.

Conclusion: The successful completion of the Lakeside Foods stand-alone freezer project is a testament to Rohde Brothers’ innovative approach and commitment to excellence. Our ability to combine cutting-edge technology with efficient project management resulted in a state-of-the-art facility that stands as a model in the food processing industry. If your project demands precision and efficiency, Rohde Brothers has the expertise to deliver.

Unique Ice Storage System, Geothermal & Waste Heat Recovery

Unique Ice Storage System, Geothermal & Waste Heat Recovery

by | Jan 30, 2018 | Projects, Uncategorized

When Masters Gallery Foods embarked on building their new cheese cutting and shredding plant in Oostburg, Wisconsin, they turned to Rohde Brothers, Inc. for a cutting-edge approach to refrigeration and HVAC systems.

Masters Gallery SiloEarly Collaboration for Innovation: Right from the conceptual stages, Masters Gallery Foods and Rohde Brothers collaborated closely. Mark Wirtz, Engineering Manager at Masters Gallery Foods, highlighted the benefits of this partnership. Together, we developed a holistic approach to the plant’s HVAC and refrigeration systems, integrating an innovative ice storage system, geothermal, and waste heat recovery. This approach not only enhanced energy efficiency but also reduced the need for ammonia, making the systems easier to maintain with lower life-cycle costs.

State-of-the-Art Facility Design: The new 2-story, 187,230 square foot facility features maintenance-friendly and energy-efficient systems. Utilizing standard equipment in unique ways, the plant stands as a model of modern food processing design.

Holistic Approach to Systems Design: Unlike traditional food processing facilities where systems are designed separately, our team took a more integrated approach. This not only reduced initial construction costs but also ongoing energy and maintenance expenses.

Customized Solutions:

  1. 3D Modeling: Facilitated an aggressive construction schedule and coordinated complex mechanical and electrical system installations.
  2. Waste Heat Utilization: Heat from chillers, hydraulic power units, and air compressors was repurposed for heating and cooling various areas, including office spaces, data and server rooms, and for snow melt and in-floor hydronic heating systems.Production Controls Interface
  3. Geothermal Pond Loop System: Provided efficient cooling and minimized the need for cooling towers.
  4. Future-Ready Refrigeration Systems: Designed for easy expansion to triple the plant’s capacity in future construction phases.
  5. Comprehensive Facility Features: Included a refrigerated bulk storage warehouse, three processing lines, packaging area, refrigerated shipping warehouse, offices, and a test kitchen.

Major Equipment Installed: The facility was equipped with a wide range of high-end machinery, including food-grade air handling units, heat-pump rooftop units, fan-coil heat pumps, evaporators, a packaged rooftop unit, chillers, ice-makers, cooling tower, and various pumps and fans.

Conclusion: Masters Gallery’s new facility is a testament to Rohde Brothers’ ability to innovate in industrial HVAC and refrigeration. Our integrated, sustainable approach has set a new standard in the industry. If you’re looking for a partner to revolutionize your facility’s systems, Rohde Brothers is at the forefront of efficient and sustainable solutions.

Mercury Marine’s Process Utility Piping Project: A Dual Award-Winning Achievement

Mercury Marine’s Process Utility Piping Project: A Dual Award-Winning Achievement

by | Jan 30, 2017 | Uncategorized

At Rohde Brothers, Inc., we’re proud to have completed a pivotal project for Mercury Marine that won both the ABC Project of Distinction and the AGC Build Wisconsin Award in 2017. This project involved comprehensive design/build HVAC and process mechanical services for a die cast addition, along with a complete rebuild of the process piping infrastructure.

The Challenge: Mercury Marine needed to modernize and expand its die casting operations. This required not only an addition to their existing facilities but also a significant overhaul of their process piping infrastructure, all while keeping the plant fully operational.

Strategic Phased Execution: The project was executed over multiple years in phases to ensure there was no disruption to ongoing plant operations. Our team worked meticulously to integrate new systems without affecting the plant’s productivity.

Client Praise: Stephen Mlinaz, Senior Facilities Manager at Mercury Marine, lauded Rohde Brothers for providing comprehensive mechanical system integration packages. He emphasized our contribution in reducing both installation and operational costs while enhancing the original performance expectations.

Customized Solutions:

  1. Complex Piping Installation: The installation of new piping in highly congested utility tunnels required careful planning and precise execution.
  2. Utility Piping Replacement: Alongside the cooling water piping, we replaced and upgraded the utility piping in the tunnels.
  3. Comprehensive Process Utility Modifications: This included alterations to potable water, non-potable water, compressed air, die lube, and wastewater systems.
  4. Future-Ready Design: Modifications were made with a focus on allowing future expansion of the die casting operations.

Conclusion: This project is a testament to Rohde Brothers’ expertise in managing complex industrial projects that require a high degree of precision and strategic planning. Our work at Mercury Marine not only met but exceeded client expectations, reducing costs and enhancing system performance. For businesses seeking a partner to undertake comprehensive mechanical system upgrades with minimal disruption, Rohde Brothers stands ready to deliver excellence.