When a production plant depends on stable temperatures, cooling isn’t just a comfort issue, it is mission critical. At BG’s Bowling Green facility, a 40-year-old water-cooled chiller was struggling to keep up, operating at roughly half capacity while the plant ran full speed.
BG needed more than a simple equipment swap. They needed a partner who could replace the chiller, navigate tight space constraints, and keep production running without interruption. Lee Company delivered a design-build solution that did exactly that: zero downtime, zero safety incidents, and a seamless transition to a modern, 300-ton Trane RTHD Optimus chiller.
The Challenge: An Aging Chiller and No Room for Error
The existing chiller had served the plant for decades, but aging equipment and reduced capacity were putting stress on operations. Taking the chiller offline for an extended period was not an option.
On top of that, the mechanical room presented serious access limitations. The doorway and surrounding structure were too narrow for a full-size chiller to pass through, and BG wanted to avoid costly structural changes.
Any solution had to:
- Maintain stable cooling while work was underway
- Address tight access and spatial constraints
- Protect people and production with strict safety and coordination
The Solution: Design-Build Precision in Tight Spaces
Lee Company approached the project as a design-build partner, planning every step around BG’s production schedule and space limitations. Over a three month window, the team:
- Demolished and removed the existing
- Trane water-cooled chiller Installed a new 300-ton
- Trane RTHD water-cooled Optimus chiller
- Reconnected and insulated the existing chilled water supply and return piping
- Installed two 3 inch conduits with 350 MCM copper conductors from the existing main distribution panel (MDP) to the new chiller
- Installed a 600 amp breaker in the MDP to serve the new unit
- Provided startup services and coordinated system balancing
Because of the narrow doorway and access path, Lee Company disassembled key chiller components, including the VFD and control panel, then reassembled them inside the mechanical room. This approach avoided structural demolition while still delivering the larger, higher capacity unit the plant needed.
Safety, Uptime, and Coordination
From day one, the project was built around uptime and safety. Pre-piped contingency hookups were put in place to maintain cooling in the event of an unexpected issue, and daily coordination meetings ensured everyone remained aligned on schedule, lifts, and tie-ins.
Lee Company:
- Coordinated crane lifts and rigging in and around an active facility
- Managed electrical subcontractors and system integration
- Oversaw startup, testing, and balancing to confirm performance
- Maintained a spotless safety record throughout the project
The result: the chiller replacement was completed without disrupting production and without a single safety incident.
The Results: Reliable Cooling and a Stronger Partnership
The BG Chiller Replacement project was a case study in precision, planning, and performance under pressure. With a modern, 300-ton chiller in place, BG gained reliable, efficient cooling capacity and peace of mind for future production demands.
Just as important, the project reaffirmed BG’s trust in Lee Company’s design-build expertise and customer-first approach, setting the stage for future plantwide cooling solutions and ongoing partnership.
If your facility is facing aging infrastructure, tight timelines, or complex access challenges, our team is ready to help you plan and execute upgrades that protect both your people and your production.
