Integrated energy retrofits delivering more than $7 million in annual savings.

Key results

Improve energy performance across different plant systems

GM wanted cleaner, more efficient operations and needed site-specific retrofits to cut utility costs and improve performance. The three plants presented different opportunities, so WEI adapted the solution to each rather than applying a single equipment swap.

Engineer the right system for each facility

WEI designed integrated retrofits for GM plants in Rochester, New York; Livonia, Michigan; and Drayton Plains, Michigan, combining steam-system conversion, boiler redesign, building pressurization and waste-heat recovery.

Use hot water, pressurization and waste heat to reduce system losses

At Rochester, WEI replaced steam distribution with closed-loop hot water. At Drayton Plains, Bigfoot removed conventional ductwork by pressurizing the building and using the building volume itself to move conditioned air.

Bigfoot also recovers waste heat for HVAC loads, keeps space temperatures more uniform, and improves indoor air quality while cutting air-circulation energy.

More than $7 million in annual savings

WEI’s retrofits across the three plants generated more than $7 million in annual savings, at an average return on investment of approximately 2.5 to 3.5 years.

WEI tailored the thermal, HVAC and controls strategy to each plant while targeting lower energy use, operating cost and better performance.

Site-specific engineering across a manufacturing portfolio