Originally published in Chiller and Cooling Best Practices Magazine

When Stellantis invested $1.48 billion to retool their Sterling Heights Assembly Plant, they didn’t just focus on production—they made energy efficiency a cornerstone of the project. The results? A 50% reduction in HVAC chilled water energy costs and some impressive sustainability wins.

Exceptional Performance Metrics

The optimized Sterling Heights Energy Center demonstrates industry-leading efficiency across multiple performance indicators:

• 0.42 kW/ton annual system efficiency (significantly exceeding ASHRAE’s 0.70 kW/ton threshold for “excellent” rating)
• 2.9 million kWh annual energy savings
• $175,000 reduction in annual energy costs
• LEED Gold certification for sustainable design

The tekWorx Difference

Stellantis and their longtime partners at tekWorx designed efficiency into the Energy Center from day one. This comprehensive approach included critical hydronic and mechanical design expertise that many optimization suppliers cannot provide—a fundamental advantage since you cannot optimize a poorly designed system. Key innovations included:

• Smart Hydronic Design: They implemented Variable Primary pumping to eliminate the “low ΔT syndrome” that plagues many chilled water systems, ensuring chillers operate at peak efficiency.
• Advanced Equipment: Six 1,000-ton YORK® YMC² magnetic bearing centrifugal chillers with variable frequency drives and QuickStart technology for rapid recovery after power failures.
• Real-Time Optimization: The tekWorx Xpress® system continuously adjusts equipment sequences and setpoints based on actual conditions, not just design day parameters.
• Continuous Monitoring: A comprehensive Xpress® dashboard provides real-time KPIs and alerts, helping operators quickly identify issues and maintain peak performance.

The Bigger Picture

The SHAP South Energy Center exemplifies how forward-thinking design can deliver both environmental and financial benefits. By prioritizing efficiency from the ground up rather than addressing it as an afterthought, Stellantis achieved results that extend well beyond energy savings—demonstrating that operational excellence and sustainability can work hand in hand.

Want the full technical details? The complete case study dives deep into the hydronic design, control algorithms, equipment specifications, and implementation strategies that made these results possible.