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Industrial
Fort Wayne, IN
Installed 2024
35% Energy Savings

Byrna Ammunition: Case Study

How Automata BMS delivered precise environmental control for manufacturing and clean room environments while significantly reducing energy costs.

Byrna Ammunition Facility

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.

Manufacturing Control Interface

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.

Previous Usage35% Reduction

Clean Room Precision

Temperature variance in clean room environments was reduced to ±0.3°F, with humidity control within ±2% RH, exceeding industry standards.

Previous Precision95% Improvement

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.

Michael Chen

"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

1

Initial Assessment

Comprehensive site survey and needs analysis to identify specific requirements for manufacturing and clean room environments.

October 2023
2

System Design

Custom BMS design with specialized controls for production areas and clean rooms, including regulatory compliance features.

November 2023
3

Installation

Phased implementation to minimize disruption to manufacturing operations, with weekend work for critical systems.

December 2023 - January 2024
4

Commissioning & Training

System testing, calibration, and staff training on the user interface and monitoring procedures.

February 2024
5

Optimization & Fine-Tuning

Data-driven adjustments based on actual production patterns and environmental requirements.

March-April 2024

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