Avon, CT

ORAFOL Americas

We helped a long-time customer upgrade their aging equipment, improving their manufacturing process and saving them money.

Value Delivered

EMCOR Services New England Mechanical (NEMSI) developed a cost-effective solution to address problems with our customer’s process chilled water systems and building pressurization.  

Our solution combined a new central chilled water plant, new 100 percent outside air make-up units, and heat recovery systems that recovered process cooling loop heat rejection to heat the outside air.

Our work on this project was recognized with two prestigious construction industry awards: Contracting Business Magazine Design-Build Award and Associated Builders and Contractors Excellence in Construction Award – Large Specialty Contractor.

Client Objectives

ORAFOL was seeking a solution that would increase its process chilled water capacity to address existing distribution problems and accommodate new capacity requirements.

They also needed to resolve an existing negative pressure problem that was affecting their manufacturing process. Additionally, they needed to replace existing rooftop units that would run quietly, addressing noise complaints from neighbors.


For this project we: 

  • Installed a new 600-ton central chilled water plant, which included:
    • Two water cooled 300-ton centrifugal chillers
    • Two cooling towers
    • Redundant pumping systems for each loop
    • Process cooling and heat recovery loops
  • Combined process loads and comfort cooling loads into a single new chiller central plant with heat recovery 
  • Replaced old equipment with new air handling units serving the expansion. The new units 
  • Helped secure $717,000 in utility incentives for our customer
  • Tripled the size of the process chilled water system, eliminated the negative pressure problems in the existing building, and addressed noise concerns
  • Overcame a three-month delay, created by unforeseen structural issues in the expansion, by successfully coordinating work with the contractors on the expansion project

Client Background

ORAFOL Americas is a manufacturer of reflective safety material for transportation, highway, military, construction, marine, and recreational markets.