Chrysler plant achieves sustainability goals with Applied Flow Technology software

COLORADO SPRINGS, Colo., March 16, 2016 –  Fiat-Chrysler Automobiles (FCA) significantly reduced energy consumption and associated greenhouse gas emissions at their top-ranked plant in the U.S. with the help of Applied Flow Technology Corporation’s (AFT) pipe flow modeling software.

Bryan Whitfield, senior energy specialist at FCA’s Manufacturing Engineering division, used the AFT Fathom software to lead the Dundee, Michigan, plant’s energy savings project. 

The Dundee team set out to optimize four of the plant’s large central coolant systems used in the machining process in hopes of reducing energy usage thereby mitigating their impact on climate change.

They created an AFT Fathom model of the coolant systems, and it produced the solution the plant needed to reduce their energy consumption. With two-thirds of US electricity generation derived from fossil fuels (U.S. DOE), energy reduction correlates directly with reduction in CO₂ emissions.

The software conservatively predicted 16% energy savings, which was enough to secure capital funding to proceed with the project. The actual energy savings achieved was 25%. The implemented project slowed down the coolant systems’ pumps, extending their lifespan and reducing waste heat.

“[This] was one of the more complex energy optimizations undertaken on process equipment at Chrysler,” Whitfield said. “I know for a fact that without AFT Fathom, the project would have never happened.”

As a result of their dramatic energy savings, the Dundee Engine Plant saved $194,000 annually in energy costs and received a $200,000 rebate from DTE Energy, their local electric services company. The project also took first place in the energy category of the FCA Environment, Health & Safety Leadership Awards 2015.

Whitfield submitted the project to AFT’s Platinum Pipe Award (PPA) contest and received the 2015 award for the Operational Benefits and Sustainability category. The award recognizes excellence in piping and ducting system modeling using AFT software.
Read the Fiat-Chrysler Automobiles case study here.

About AFT          

Founded in 1993, Applied Flow Technology has grown to be a leader in the pipe flow modeling software market. With a primary focus on developing high quality fluid flow analysis software, AFT has a comprehensive line of products for the analysis and design of piping and ducting systems.

With channel partners around the world and customers in more than 70 countries, AFT software has helped companies in many industries design safer, more efficient systems and solve operational problems.

About FCA

Fiat Chrysler Automobiles, the seventh-largest automaker in the world, designs, engineers, manufactures and sells passenger cars, light commercial vehicles, components and production systems worldwide.