Sometimes a supply chain problem turns into an opportunity to improve an existing equipment design.
That's exactly what happened when an industrial equipment manufacturer approached BA Associates looking for an alternative to the traditional tube-and-fin heat exchangers used in their equipment.
Their existing supplier was experiencing extended lead times, creating challenges for their production schedule.
The initial goal was simple: find a reliable heat exchanger supplier without redesigning the equipment.
What started as a lead-time issue ultimately resulted in a new heat exchanger design, simplified assembly, and a 20% reduction in component costs.
Replacing Traditional Tube-and-Fin Heat Exchangers
Tube-and-fin heat exchangers are commonly used in air-to-liquid cooling applications. Their design allows heat to transfer between a liquid circulating through tubes and air moving across the finned surfaces.
For this OEM, the existing tube-and-fin design had been part of their equipment for years.
Rather than simply sourcing an identical replacement, BA Associates evaluated a bar-and-plate heat exchanger as an alternative.
The challenge was finding a solution that would fit within the existing equipment configuration without requiring significant modifications.
A Custom Heat Exchanger Designed Around the OEM's Equipment
Working with the customer, we developed a bar-and-plate heat exchanger package that addressed several aspects of their production process.
Matching the Existing Footprint
The replacement heat exchanger was designed to fit within the space occupied by the original tube-and-fin unit, minimizing changes to the OEM's equipment layout.
Updating the Connections
The original heat exchanger connections weren't an ideal match for the fittings being installed at the customer's factory.
We incorporated the appropriate connections into the new design, reducing the need for additional adaptation during assembly.
Factory-Installed Cooling Fans
Previously, the OEM received heat exchangers and installed the cooling fans separately during production.
With the new package, the fans are installed before shipment.
The customer now receives a more complete assembly, reducing the work required on their production floor.
The Result: 20% Cost Savings and Repeat Orders
The new bar-and-plate heat exchanger package delivered approximately 30% cost savings compared with the OEM's previous tube-and-fin solution.
In addition to the lower component cost, the customer benefited from a heat exchanger package designed to integrate more easily into their manufacturing process.
The project has since moved beyond the initial order, with approximately 30 units ordered to date.
What began as an effort to resolve supplier lead-time challenges became an opportunity to improve both component sourcing and equipment assembly.
When Should OEMs Consider Alternative Heat Exchanger Designs?
Just because a particular heat exchanger design has worked for years doesn't necessarily mean it's still the best option.
For OEMs manufacturing industrial cooling and thermal equipment, revisiting heat exchanger selection can uncover opportunities to improve:
Component cost and supplier availability
Equipment footprint and connection compatibility
Factory assembly time
Integration of fans and other accessories
Overall manufacturing efficiency
Of course, changing heat exchanger technologies requires evaluating thermal performance, airflow, pressure drop, materials, and operating conditions.
A bar-and-plate design isn't automatically the right replacement for every tube-and-fin heat exchanger. The selection needs to make sense for the application.
OEM Heat Exchanger Solutions from BA Associates
BA Associates works with OEM engineers and industrial equipment manufacturers throughout New England and the Northeast to help identify heat exchanger solutions for their applications.
Whether the challenge involves long lead times, component costs, custom connections, or equipment integration, we can help evaluate alternative designs and coordinate with our manufacturing partners.
Sometimes the best way to improve an existing machine is to take another look at the components that have always been there.
Have an OEM heat exchanger application worth reviewing?
Contact BA Associates to discuss your requirements.
(603) 210-2479
mike@bonardi.com
www.ba-assoc.com