Byrna Ammunition: Case Study
How Automata BMS delivered precise environmental control for manufacturing and clean room environments while significantly reducing energy costs.
Client Overview
Byrna Ammunition is a specialized manufacturing facility that produces non-lethal self-defense ammunition. The Fort Wayne location includes both production areas and clean room environments for precision manufacturing and quality control. The facility requires strict environmental controls to maintain product quality and manufacturing precision.
Facility Type
Industrial Manufacturing
Location
Fort Wayne, Indiana
Size
35,000 square feet
The Challenge
Byrna Ammunition faced several challenges in maintaining optimal environmental conditions for their manufacturing processes:
Clean Room Requirements
Maintaining precise temperature, humidity, and air quality in clean room environments for quality control and testing.
Energy Efficiency
High energy costs associated with maintaining specialized manufacturing environments and ventilation systems.
Ventilation Control
Need for specialized ventilation in production areas to maintain air quality and safety standards.
Regulatory Compliance
Meeting strict regulatory requirements for manufacturing environments while optimizing operational costs.
The Solution
Automata BMS implemented a comprehensive building management system tailored to the specific needs of industrial manufacturing and clean room environments:
Production DOAS
Captive Air indirect fired makeup air unit with DX cooling for the main production area, providing precise ventilation and temperature control.
Key Features:
- Variable airflow based on production schedules
- Demand-controlled ventilation
- Energy recovery ventilation
Clean Room DOAS
Specialized DOAS system for the clean room environment, averaging conditions across 5 rooms with captive air indirect fired makeup air and DX cooling.
Key Features:
- HEPA filtration monitoring
- Precise humidity control
- Pressure differential monitoring
Advanced Control Features
Production-Based Scheduling
HVAC operation synchronized with production schedules to optimize energy use during different manufacturing phases.
Environmental Monitoring
Continuous monitoring of temperature, humidity, particulate levels, and air quality with automated alerts for out-of-range conditions.
Energy Optimization
Intelligent algorithms that balance energy efficiency with strict environmental requirements for manufacturing processes.
Compliance Reporting
Automated data logging and reporting to demonstrate regulatory compliance for manufacturing environments.
Specialized Manufacturing Controls
The Automata BMS interface provides specialized controls for manufacturing environments, including clean room monitoring, production area ventilation, and energy usage tracking.
The Results
The implementation of Automata BMS at Byrna Ammunition delivered significant improvements in both environmental control and operational efficiency:
Energy Efficiency
The facility achieved a 35% reduction in energy costs through optimized HVAC operation, production-based scheduling, and demand-controlled ventilation.
Clean Room Precision
Temperature variance in clean room environments was reduced to ±0.3°F, with humidity control within ±2% RH, exceeding industry standards.
Production Quality
Product quality metrics improved by 18% due to more consistent environmental conditions in manufacturing areas.
Regulatory Compliance
Automated documentation and reporting simplified regulatory compliance and reduced administrative burden.
Operational Insights
Data analytics provided valuable insights that helped optimize production schedules and environmental settings.
"The Automata BMS system has been a game-changer for our manufacturing facility. The precise environmental control in our clean rooms has improved product quality and consistency, while the energy savings have exceeded our expectations. The system's ability to adapt to our production schedules has been particularly valuable."
Michael Chen
Operations Manager, Byrna Ammunition
ROI Analysis
Initial Investment
$110,000
Complete BMS implementation
Annual Savings
$42,500
Energy and operational costs
Payback Period
2.6 Years
Faster than industry average
The Automata BMS implementation at Byrna Ammunition delivered a strong return on investment, with the system paying for itself in less than three years. When factoring in the improvements in product quality and regulatory compliance, the total value delivered significantly exceeds the direct financial benefits.
Implementation Timeline
Initial Assessment
Comprehensive site survey and needs analysis to identify specific requirements for manufacturing and clean room environments.
System Design
Custom BMS design with specialized controls for production areas and clean rooms, including regulatory compliance features.
Installation
Phased implementation to minimize disruption to manufacturing operations, with weekend work for critical systems.
Commissioning & Training
System testing, calibration, and staff training on the user interface and monitoring procedures.
Optimization & Fine-Tuning
Data-driven adjustments based on actual production patterns and environmental requirements.
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