At the Toyota automobile manufacturing facility in Kentucky, Facility and Paint Team Members knew their paint booths were using tremendous amounts of energy to condition the 100% outside air booth supply system. Fosdick & Hilmer was retained to investigate the technical and economic feasibility of recovering heat and moisture released to atmosphere from the paint booths. The study investigated various available technologies and determined that the best application for this facility was an enthalpy recovery system. Based on a conceptual design and plant operating data, an economic analysis was made that demonstrated the economic feasibility of the project. A design-build contract was then issued for construction of the enthalpy recovery system with Fosdick & Hilmer as the Engineer-of-Record.
The system utilizes advanced monitoring and control systems and introduction of enthalpy recovery wheels in the air supply house of the paint booth. Additional work was required on other ASH/booth subsystems to integrate the new technology with the existing systems. Fosdick & Hilmer prepared specifications for the purchase of all major mechanical and electrical equipment, prepared construction drawings, developed the sequence of operations, and designed and programmed the control system.
Start-up and commissioning services were provided for all mechanical, electrical power, and instrumentation/control systems designed for the project. This installation is being used by Toyota as a technology prototype that will be adapted and installed in other North American manufacturing plants. Construction was completed in 2005.