Manufacturing facilities depend on reliable HVAC systems to support production, protect equipment and maintain safe working environments. When maintenance becomes reactive instead of proactive, emergency repairs can quickly become the norm and place additional strain on facility teams.
That was the challenge facing Ardagh Glass, a manufacturer of wine bottles serving California’s wine industry and customers across the United States. Their maintenance staff was already balancing multiple priorities, leaving little time to stay ahead of HVAC issues. As emergency service calls increased, the need for a long-term solution became clear.
A Facility Stretched by Reactive Service
Ardagh Glass operates a large-scale manufacturing environment where dependable building systems are essential to supporting production. Like many industrial facilities, their maintenance staff was responsible for more than just the HVAC equipment. Every day brought a new set of priorities, which made it difficult to dedicate the time needed to proactively maintain the facility’s mechanical systems.
Over time, the HVAC service became increasingly reactive. They repaired equipment when problems occurred, but there was little opportunity to identify developing issues before they resulted in emergency service calls.
While the approach kept the equipment operating, it also created uncertainty. Emergency repairs interrupted schedules, consumed valuable resources and made it difficult for the maintenance team to focus on other operational priorities.
The facility needed a proactive HVAC partner who could help them develop a long-term strategy for improving system reliability.
Building a Preventive HVAC Maintenance Program
Our team at BMI began by evaluating the facility’s HVAC systems and working closely with the Ardagh Glass team to better understand their operational goals and maintenance challenges.
Rather than simply responding to service requests as they came in, we implemented a customized commercial HVAC maintenance program designed to improve equipment performance and reduce the likelihood of unexpected failures.
We made routine inspections, scheduled maintenance and ongoing system evaluations the foundation of a proactive approach and allowed potential issues to be identified before they became costly emergencies.
This shift from reactive service to preventive maintenance created immediate value for the facility. Instead of wondering when the next breakdown would occur, the maintenance team could confidently plan around scheduled service while focusing their attention on other important responsibilities throughout the plant.
A Measurable Improvement
The impact of the maintenance program became clear during the first year.
Emergency HVAC service needs were nearly eliminated, creating a more predictable maintenance schedule and allowing facility personnel to better manage their time and resources. The facility experienced improved system reliability and fewer unexpected interruptions, helping support continuous production and day-to-day operations.
The results extended beyond the HVAC equipment itself. By reducing emergency service calls, the internal maintenance team gained valuable time to focus on projects that supported the overall operation of the plant.
Looking Beyond the Immediate Project
As our partnership continued, Ardagh Glass planned a major HVAC replacement project. Rather than simply replacing the existing system as originally designed, we evaluated the project to determine whether there was a better long-term solution.
After reviewing the facility and its operational needs, we developed an alternative design that improved the project in several important ways.
The redesigned solution provided:
- Safer and more convenient access for future maintenance
- Backup system redundancy to support future operational needs
- Approximately 30% savings compared to the original project budget
Instead of delivering only a replacement, we helped Ardagh Glass make an investment that would continue providing value long after the project was complete.
Building Long-Term Value Through Partnership
Every manufacturing facility has its own challenges, but one thing remains consistent. A proactive approach to commercial HVAC maintenance helps reduce unexpected downtime, improve system reliability and support smarter long-term decisions.
By working alongside our clients as their trusted mechanical partner, we help create HVAC strategies that keep operations running today while preparing facilities for tomorrow’s needs.
Have a facility that needs help? Contact our team to learn more, or discover the best route for your company with our self-guided sales experience.
