U.S. Chiller Production and Testing in Daleville
Since chiller production began in Daleville, Munters have continued to invest in people, equipment and production processes to strengthen product quality, improve production consistency and increase production efficiency. The Daleville production site includes two factories, with the larger of the two dedicated exclusively to chiller production.
The production site combines chiller production, end-of-line testing, in-house condenser coil rolling and controlled-condition laboratory testing. These capabilities support the production and continued development of data center chillers for demanding applications.
U.S. Production of Chillers for All Types of Data Centers
Bringing chiller production to Daleville was the starting point for continued investment in the production site’s people, equipment and production processes.
These investments are intended to strengthen product quality, improve consistency and increase production efficiency. From production equipment and testing capabilities to skilled employees and standardized processes, each improvement supports the production of chillers for data center applications.
Continuous Improvement Through Lean Six Sigma
Lean Six Sigma has played a key role in efforts to improve efficiency and consistency in chiller production.
By applying data-driven decision-making and Lean Six Sigma methodologies, the Daleville team has streamlined production, reduced variation, eliminated waste and standardized processes throughout the production site.
Continuous improvement also extends beyond the Lean Six Sigma team. Employees are encouraged to identify opportunities to improve quality, reduce waste and make production processes more efficient. These incremental improvements strengthen the operation and help ensure that each chiller is built to the same high standard.
End-of-Line Testing on Every Flow Lane
One of the most significant production enhancements is comprehensive end-of-line testing on every flow lane.
Rather than testing a sample of units or only portions of the system, every flow lane is validated before a chiller leaves the production site. This allows the team to verify mechanical, electrical and control system performance while confirming that every refrigerant circuit is operating as designed.
For customers, this means greater confidence during commissioning, fewer surprises in the field and assurance that every unit has been thoroughly validated before shipment.
Greater Control Through In-House Condenser Coil Rolling
The circular condenser design used on the chillers produced in Daleville requires each condenser coil to be rolled to precise specifications before assembly.
By performing this process in-house, Munters has greater control over dimensional accuracy, production consistency and quality. Maintaining control of this fabrication step helps ensure that each coil meets its design specifications before becoming part of the finished chiller.
Advanced Chiller Testing in Controlled Conditions
The Daleville chiller test lab supports customer validation, engineering development and continuous product improvement.
The laboratory includes an environmental chamber capable of recreating a wide range of operating conditions. The laboratory can test chillers up to 3 MW at air temperatures from 55°F to 135°F (12.7°C to 57.2°C).
By replicating different ambient temperatures and operating scenarios, engineers can evaluate chiller performance and gather meaningful performance data before products are deployed in the field.
Supporting Customer Validation and Learning
The controlled testing environment allows engineers to verify:
- Performance under varying ambient and fluid operating envelopes
- Controls interface functionality and integration
- Dynamic operating scenarios, including power interruptions and rapid load changes
The Daleville site also provides a platform for customer-facing validation and learning, with testing capabilities that can support customer visits, demonstrations and future training activities.
Supporting Product Development
Beyond customer validation, the laboratory provides a platform for ongoing product development and continuous improvement.
Engineering teams can use the production site for:
- Optimization of advanced chiller control strategies
- Evaluation of new components and system configurations
- Long-term reliability and durability testing
- Performance validation of future product enhancements
The controlled environment enables engineers to evaluate new technologies, refine system designs and optimize performance before enhancements reach production.
Recovering Energy From the Testing Process
he chiller test lab reuses energy within the test process to reduce the overall energy required for the test.
Chilled water from the chiller under test is used to cool hot air from the condenser back to the target test conditions.
A Platform for Continued Development
By bringing production, end-of-line testing, laboratory testing and engineering capabilities together in Daleville, Munters supports the continued production, development and validation of chillers for demanding data center applications.
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Production Site Overview
- Location: Daleville, Virginia, U.S.
- Primary focus: Production and testing of chillers
- Production approach: Lean Six Sigma practices
- Production validation: End-of-line testing on every flow lane
- In-house capability: Condenser coil rolling
- Laboratory capacity: Chiller testing up to 3 MW
- Air temperature range: 55°F to 135°F (12.7°C to 57.2°C)
- Energy feature: Energy reuse within the chiller test process