{"id":128602,"date":"2025-01-07T00:03:11","date_gmt":"2025-01-07T12:03:11","guid":{"rendered":"https:\/\/www.controleng.com\/new-facility-six-net-zero-benefits-seven-smart-manufacturing-methods\/"},"modified":"2025-04-23T20:22:14","modified_gmt":"2025-04-24T01:22:14","slug":"new-facility-six-net-zero-benefits-seven-smart-manufacturing-methods","status":"publish","type":"post","link":"https:\/\/www.controleng.com\/new-facility-six-net-zero-benefits-seven-smart-manufacturing-methods\/","title":{"rendered":"New facility: Six net zero benefits, seven smart manufacturing methods\u00a0"},"content":{"rendered":"<p>&nbsp;<\/p>\n<div class=\"learn-obj\">\n<div class=\"top-one\"><\/div>\n<div class=\"top-two\"><\/div>\n<h4>Learning Objectives<\/h4>\n<ul>\n<li>Understand six benefits to automated, advanced manufacturing and warehousing facility, seven smart factory attributes.<\/li>\n<li>Learn about new automated manufacturing, educational labs, sustainability methods.<\/li>\n<li>Explore a $100 million automated, advanced manufacturing and motor, VFD and electrical training facility.<\/li>\n<\/ul>\n<div class=\"bottom\"><\/div>\n<\/div>\n<h2><span data-contrast=\"auto\">Automated smart manufacturing, net zero facility and motor-VFD training insights<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/h2>\n<ul>\n<li><span data-contrast=\"auto\">Six benefits to a new automated, advanced manufacturing and warehousing facility are explained, along with seven smart factory attributes.<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/li>\n<li><span data-contrast=\"auto\">A new ABB automated manufacturing site in New Berlin, Wisconsin has motor and variable frequency drive (VFD) educational labs; learn about demonstrated sustainability methods.<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/li>\n<li><span data-contrast=\"auto\">Tour a $100 million ABB automated, advanced manufacturing and educational facility with text, photos and videos.<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/li>\n<\/ul>\n<hr \/>\n<p><span data-contrast=\"auto\">Customers can see how <\/span><a href=\"https:\/\/www.abb.com\/\" target=\"_blank\" rel=\"noopener\"><span data-contrast=\"none\">ABB<\/span><\/a> <span data-contrast=\"auto\">technologies are saving energy in a new $100 million advanced manufacturing facility, customer experience center and innovation lab that combines and expands two other Wisconsin sites and adds adjacent warehousing space. At the ribbon-cutting event Oct. 29, company executives explained how ABB motors, drives, and other products can show customers how to effectively and efficiently apply advanced technologies to meet 2030 sustainability and decarbonization goals. The facility (see videos, photos) will employ more than 700 workers with an additional 100 jobs within three years in a phased opening and expansion.\u00a0<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/p>\n<figure id=\"attachment_548222\" aria-describedby=\"caption-attachment-548222\" style=\"width: 765px\" class=\"wp-caption alignnone\"><img loading=\"lazy\" decoding=\"async\" class=\"wp-image-548222 size-full\" src=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/01\/CTL2411_WEB_ABB-New-Berlin-Fig1-Building-exterior-mHoske-scaled-e1736204115529-1.jpg\" alt=\"ABB Drives USA HQ (Lincoln Facility) held an open house, ribbon-cutting ceremony and facility tour for staff, customers, local educators, government representatives and media Oct. 29. The New Berlin, Wisconsin, facility, over 500,000 square feet, showcases the future of sustainable manufacturing and job growth in Wisconsin, officials said. Courtesy: Mark T. Hoske, Control Engineering, WTWH Media\" width=\"765\" height=\"1020\" \/><figcaption id=\"caption-attachment-548222\" class=\"wp-caption-text\">ABB Drives USA HQ (Lincoln Facility) held an open house, ribbon-cutting ceremony and facility tour for staff, customers, local educators, government representatives and media Oct. 29. The New Berlin, Wisconsin, facility, over 500,000 square feet, showcases the future of sustainable manufacturing and job growth in Wisconsin, officials said. Courtesy: Mark T. Hoske, Control Engineering, WTWH Media<\/figcaption><\/figure>\n<h2><span data-contrast=\"auto\">Six benefits to automated, advanced manufacturing and warehousing facility<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/h2>\n<h3><span data-contrast=\"auto\">At the event, ABB explained six key benefits to employees, elected officials, education leaders and media that the site:<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/h3>\n<ul>\n<li data-leveltext=\"\uf0b7\" data-font=\"Symbol\" data-listid=\"1\" data-list-defn-props=\"{&quot;335552541&quot;:1,&quot;335559685&quot;:720,&quot;335559991&quot;:360,&quot;469769226&quot;:&quot;Symbol&quot;,&quot;469769242&quot;:[8226],&quot;469777803&quot;:&quot;left&quot;,&quot;469777804&quot;:&quot;\uf0b7&quot;,&quot;469777815&quot;:&quot;hybridMultilevel&quot;}\" data-aria-posinset=\"1\" data-aria-level=\"1\">\n<h3><span data-contrast=\"auto\">Supports future growth in ABB\u2019s largest market with production of electric drive technologies used in a variety of industries. The highly automated, advanced manufacturing facility is expected to attract engineering and other skilled workforce talent.<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/h3>\n<\/li>\n<\/ul>\n<ul>\n<li data-leveltext=\"\uf0b7\" data-font=\"Symbol\" data-listid=\"1\" data-list-defn-props=\"{&quot;335552541&quot;:1,&quot;335559685&quot;:720,&quot;335559991&quot;:360,&quot;469769226&quot;:&quot;Symbol&quot;,&quot;469769242&quot;:[8226],&quot;469777803&quot;:&quot;left&quot;,&quot;469777804&quot;:&quot;\uf0b7&quot;,&quot;469777815&quot;:&quot;hybridMultilevel&quot;}\" data-aria-posinset=\"2\" data-aria-level=\"1\">\n<h3><span data-contrast=\"auto\">Creates a new manufacturing and customer experience facility with digital technologies that help ABB meeting sustainability goals for 2030 and beyond.<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/h3>\n<\/li>\n<\/ul>\n<ul>\n<li data-leveltext=\"\uf0b7\" data-font=\"Symbol\" data-listid=\"1\" data-list-defn-props=\"{&quot;335552541&quot;:1,&quot;335559685&quot;:720,&quot;335559991&quot;:360,&quot;469769226&quot;:&quot;Symbol&quot;,&quot;469769242&quot;:[8226],&quot;469777803&quot;:&quot;left&quot;,&quot;469777804&quot;:&quot;\uf0b7&quot;,&quot;469777815&quot;:&quot;hybridMultilevel&quot;}\" data-aria-posinset=\"3\" data-aria-level=\"1\">\n<h3><span data-contrast=\"auto\">Applies geothermal heating and modern HVAC system designed to recycle waste heat, eliminate natural gas use and reduce energy use more than 45%.<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/h3>\n<\/li>\n<\/ul>\n<ul>\n<li data-leveltext=\"\uf0b7\" data-font=\"Symbol\" data-listid=\"1\" data-list-defn-props=\"{&quot;335552541&quot;:1,&quot;335559685&quot;:720,&quot;335559991&quot;:360,&quot;469769226&quot;:&quot;Symbol&quot;,&quot;469769242&quot;:[8226],&quot;469777803&quot;:&quot;left&quot;,&quot;469777804&quot;:&quot;\uf0b7&quot;,&quot;469777815&quot;:&quot;hybridMultilevel&quot;}\" data-aria-posinset=\"4\" data-aria-level=\"1\">\n<h3><span data-contrast=\"auto\">Saves transportation costs and associated emissions by locating a warehouse distribution center on the campus.\u00a0<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/h3>\n<\/li>\n<\/ul>\n<ul>\n<li data-leveltext=\"\uf0b7\" data-font=\"Symbol\" data-listid=\"1\" data-list-defn-props=\"{&quot;335552541&quot;:1,&quot;335559685&quot;:720,&quot;335559991&quot;:360,&quot;469769226&quot;:&quot;Symbol&quot;,&quot;469769242&quot;:[8226],&quot;469777803&quot;:&quot;left&quot;,&quot;469777804&quot;:&quot;\uf0b7&quot;,&quot;469777815&quot;:&quot;hybridMultilevel&quot;}\" data-aria-posinset=\"5\" data-aria-level=\"1\">\n<h3><span data-contrast=\"auto\">Meets requirements of the Build America Buy America Act (BABAA).<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/h3>\n<\/li>\n<\/ul>\n<ul>\n<li data-leveltext=\"\uf0b7\" data-font=\"Symbol\" data-listid=\"1\" data-list-defn-props=\"{&quot;335552541&quot;:1,&quot;335559685&quot;:720,&quot;335559991&quot;:360,&quot;469769226&quot;:&quot;Symbol&quot;,&quot;469769242&quot;:[8226],&quot;469777803&quot;:&quot;left&quot;,&quot;469777804&quot;:&quot;\uf0b7&quot;,&quot;469777815&quot;:&quot;hybridMultilevel&quot;}\" data-aria-posinset=\"6\" data-aria-level=\"1\">\n<h3><span data-contrast=\"auto\">Is important for industrial, power, transportation and building sectors.<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/h3>\n<\/li>\n<\/ul>\n<figure id=\"attachment_548223\" aria-describedby=\"caption-attachment-548223\" style=\"width: 765px\" class=\"wp-caption alignnone\"><img loading=\"lazy\" decoding=\"async\" class=\"wp-image-548223 size-full\" src=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/01\/CTL2411_WEB_ABB-New-Berlin-Fig2-Kelly-Kling-mHoske-scaled-e1736204141569-1.jpg\" alt=\"Kelly Kling, drives site leader and head of finance for U.S. ABB motion business, said, \u201cIt is important for business, government and educational institutions to work together to prepare the workforce for modern manufacturing,\u201d then detailed how the new ABB New Berlin, Wisconsin, facility does that. Courtesy: Mark T. Hoske, Control Engineering, WTWH Media\" width=\"765\" height=\"1020\" \/><figcaption id=\"caption-attachment-548223\" class=\"wp-caption-text\">Kelly Kling, drives site leader and head of finance for U.S. ABB motion business, said, \u201cIt is important for business, government and educational institutions to work together to prepare the workforce for modern manufacturing,\u201d then detailed how the new ABB New Berlin, Wisconsin, facility does that. Courtesy: Mark T. Hoske, Control Engineering, WTWH Media<\/figcaption><\/figure>\n<h2><span data-contrast=\"auto\">Automated manufacturing, educational labs, sustainability benefits explained <\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/h2>\n<p><span data-contrast=\"auto\">ABB executives and government representatives discussed the importance of the new facility investments. (ABB has about 20,000 U.S. employees.)\u00a0<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/p>\n<p><span data-contrast=\"auto\">Kelly Kling, drives site leader and head of finance for U.S. ABB motion business: \u201cIt is important for business, government and educational institutions to work together to prepare the workforce for modern manufacturing. STEM education will better prepare the nation for the high demand of electrical and mechanical engineers, contractors and automation technicians. It is important for ABB, our customers and will build a stronger America.\u201d<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/p>\n<p><span data-contrast=\"auto\">In separate comments to <\/span><a href=\"https:\/\/www.controleng.com\" target=\"_blank\" rel=\"noopener\"><i><span data-contrast=\"auto\">Control Engineering<\/span><\/i><\/a><span data-contrast=\"auto\"> and other WTWH Media publications, Kling said skilled labor is available in the area along with partners and educational resources, including access to trade programs. The facility includes failure analysis and application testing, a showcase for ABB products, in-person and remote learning and, eventually, a customer experience center.\u00a0<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/p>\n<figure id=\"attachment_548224\" aria-describedby=\"caption-attachment-548224\" style=\"width: 765px\" class=\"wp-caption alignnone\"><img loading=\"lazy\" decoding=\"async\" class=\"wp-image-548224 size-full\" src=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/01\/CTL2411_WEB_ABB-New-Berlin-Fig3-Brandon-Spencer-mHoske-scaled-e1736204164148-1.jpg\" alt=\"Brandon Spencer, president of ABB\u2019s motion business area sustainable manufacturing (new head of motion, globally) said ABB has invested $14 billion in 10 years in infrastructure and people to support U.S. manufacturing, including the New Berlin, Wisconsin site, enabling people to buy from and build in America. Courtesy: Mark T. Hoske, Control Engineering, WTWH Media\" width=\"765\" height=\"1020\" \/><figcaption id=\"caption-attachment-548224\" class=\"wp-caption-text\">Brandon Spencer, president of ABB\u2019s motion business area sustainable manufacturing (new head of motion, globally) said ABB has invested $14 billion in 10 years in infrastructure and people to support U.S. manufacturing, including the New Berlin, Wisconsin site, enabling people to buy from and build in America. Courtesy: Mark T. Hoske, Control Engineering, WTWH Media<\/figcaption><\/figure>\n<p><span data-contrast=\"auto\">While the facility geothermal system is pricier up front, and the ROI is longer, \u201cWe practice what preach. We\u2019re protecting the environment, using automation, smart manufacturing lines, insulation, building management system (BMS) intelligence and a state-of-the-art mechanical room,\u201d she said.<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/p>\n<p><span data-contrast=\"auto\">On the solar power roof-top installation, Kling said, it\u2019s a three-to-five-year ROI; geothermal ROI we haven\u2019t worked through, yet, but that\u2019s more like 15-20 years.<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/p>\n<p><span data-contrast=\"auto\">Because government contracts require a certain percentage of U.S. sourced and purchased, this project helps ABB U.S. sales and customers.<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/p>\n<figure id=\"attachment_548225\" aria-describedby=\"caption-attachment-548225\" style=\"width: 765px\" class=\"wp-caption alignnone\"><img loading=\"lazy\" decoding=\"async\" class=\"wp-image-548225 size-full\" src=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/01\/CTL2411_WEB_ABB-New-Berlin-Fig4-Tuomo-Hoysniemi-mHoske-scaled-e1736204195774-1.jpg\" alt=\"Tuomo Hoysniemi, president of ABB\u2019s U.S. motion business area and global drive products division, said ABB technology is being used to run a cleaner factory and integrate with building design features at the New Berlin, Wisconsin, site, such as solar power, geothermal heat pump and modern HVAC systems and ABB advanced building controls, to help ABB meet its 2030 sustainability goals. Courtesy: Mark T. Hoske, Control Engineering, WTWH Media\" width=\"765\" height=\"1020\" \/><figcaption id=\"caption-attachment-548225\" class=\"wp-caption-text\">Tuomo Hoysniemi, president of ABB\u2019s U.S. motion business area and global drive products division, said ABB technology is being used to run a cleaner factory and integrate with building design features at the New Berlin, Wisconsin, site, such as solar power, geothermal heat pump and modern HVAC systems and ABB advanced building controls, to help ABB meet its 2030 sustainability goals. Courtesy: Mark T. Hoske, Control Engineering, WTWH Media<\/figcaption><\/figure>\n<p><span data-contrast=\"auto\">For staffing, Kling said, \u201cWe\u2019re building to the 700 number.\u201d About 300 people work in the office at present, she said, and production is moving over from <\/span><span data-contrast=\"auto\">two<\/span> <span data-contrast=\"none\">one <\/span><span data-contrast=\"auto\">facilitie<\/span><span data-contrast=\"auto\">s facility in the area. Manufacturing areas include low- and medium-voltage drives and cabinet drives, along with a repair shop. The numbers also increase during summer with contractor workforce in the line and functional areas. Adjacent to the ABB building is a logistics facility operated by a third party.<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/p>\n<p><span data-contrast=\"auto\">Brandon Spencer, president of ABB\u2019s motion business area sustainable manufacturing (new head of motion, globally): \u201cABB is a technology leader in electrification and automation and the U.S. market is an important growth engine for our business. Investment in this modern manufacturing facility gives ABB access to a highly qualified workforces, strengthens localized supply chains and keeps us close to our customers.\u201d<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/p>\n<figure id=\"attachment_548226\" aria-describedby=\"caption-attachment-548226\" style=\"width: 1020px\" class=\"wp-caption alignnone\"><img loading=\"lazy\" decoding=\"async\" class=\"wp-image-548226 size-full\" src=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/01\/CTL2411_WEB_ABB-New-Berlin-Fig5-Showcase-area-mHoske-scaled-e1736204227265-1.jpg\" alt=\"ABB product showcase planned on-site: At the ABB New Berlin, Wisconsin, facility the large open area beyond the main entrance will become a showcase for ABB products, according to comments to Control Engineering from Kelly Kling, drives site leader and head of finance for U.S. ABB motion business. Upper right are stairs to the mechanical room. Courtesy: Mark T. Hoske, Control Engineering, WTWH Media\" width=\"1020\" height=\"765\" \/><figcaption id=\"caption-attachment-548226\" class=\"wp-caption-text\">ABB product showcase planned on-site: At the ABB New Berlin, Wisconsin, facility the large open area beyond the main entrance will become a showcase for ABB products, according to comments to Control Engineering from Kelly Kling, drives site leader and head of finance for U.S. ABB motion business. Upper right are stairs to the mechanical room. Courtesy: Mark T. Hoske, Control Engineering, WTWH Media<\/figcaption><\/figure>\n<p><span data-contrast=\"auto\">During the event, Spencer said ABB has invested $14 billion in 10 years in infrastructure and people to support U.S. manufacturing, enabling people to buy from and build in America. He reemphasized the advantages to of a highly qualified workforce, supply chain and markets. The facility provides lean and clean infrastructure sustainability: \u201cWe\u2019re walking the walk. Doing it ourselves for own facilities, serving customers with higher availability. This is part of the energy transition across the U.S. We\u2019re proud to have the team here. Motors and drives play key roles across all the megatrends, and we\u2019re proud to manufacture here in New Berlin. We provide energy with a lower carbon footprint. We\u2019re proud of Kelly and the team here to put together this facility in a sustainable way.\u201d\u00a0<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/p>\n<h2><span data-contrast=\"auto\">More ways to design a building for net zero carbon emissions<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/h2>\n<p><span data-contrast=\"auto\">Tuomo Hoysniemi, president of ABB\u2019s U.S. motion business area and global drive products division: \u201cABB is strengthening America\u2019s infrastructure and introducing new, cleaner technologies to help customers boost competitiveness while lowering their carbon footprints. We are also using technology to run our own factory cleaner with building design features such as solar power, geothermal heat pump and modern HVAC systems and advanced building controls. The innovations will help ABB meet its own 2030 sustainability goals.\u201d<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/p>\n<figure id=\"attachment_548227\" aria-describedby=\"caption-attachment-548227\" style=\"width: 1020px\" class=\"wp-caption alignnone\"><img loading=\"lazy\" decoding=\"async\" class=\"wp-image-548227 size-full\" src=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/01\/CTL2411_WEB_ABB-New-Berlin-Fig6-Training-area-mHoske-scaled-e1736204252183-1.jpg\" alt=\"ABB training, classroom and in labs, expands with the ABB advanced manufacturing facility, customer experience center and innovation lab in New Berlin, Wisconsin. Workstations in the middle, electrical panels on the back wall and cart of variable frequency drives (VFDs), right, can help training, along with classes in progress, not shown, said Jeff Fell, application engineering manager. Courtesy: Mark T. Hoske, Control Engineering, WTWH Media\" width=\"1020\" height=\"765\" \/><figcaption id=\"caption-attachment-548227\" class=\"wp-caption-text\">ABB training, classroom and in labs, expands with the ABB advanced manufacturing facility, customer experience center and innovation lab in New Berlin, Wisconsin. Workstations in the middle, electrical panels on the back wall and cart of variable frequency drives (VFDs), right, can help training, along with classes in progress, not shown, said Jeff Fell, application engineering manager. Courtesy: Mark T. Hoske, Control Engineering, WTWH Media<\/figcaption><\/figure>\n<h3><span data-contrast=\"auto\">Hoysniemi presentation noted site details helping New Berlin get to net zero.<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/h3>\n<ul>\n<li data-leveltext=\"\uf0b7\" data-font=\"Symbol\" data-listid=\"3\" data-list-defn-props=\"{&quot;335552541&quot;:1,&quot;335559685&quot;:720,&quot;335559991&quot;:360,&quot;469769226&quot;:&quot;Symbol&quot;,&quot;469769242&quot;:[8226],&quot;469777803&quot;:&quot;left&quot;,&quot;469777804&quot;:&quot;\uf0b7&quot;,&quot;469777815&quot;:&quot;hybridMultilevel&quot;}\" data-aria-posinset=\"1\" data-aria-level=\"1\">\n<h3><span data-contrast=\"auto\">Eight electric vehicle charging stations<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/h3>\n<\/li>\n<\/ul>\n<ul>\n<li data-leveltext=\"\uf0b7\" data-font=\"Symbol\" data-listid=\"3\" data-list-defn-props=\"{&quot;335552541&quot;:1,&quot;335559685&quot;:720,&quot;335559991&quot;:360,&quot;469769226&quot;:&quot;Symbol&quot;,&quot;469769242&quot;:[8226],&quot;469777803&quot;:&quot;left&quot;,&quot;469777804&quot;:&quot;\uf0b7&quot;,&quot;469777815&quot;:&quot;hybridMultilevel&quot;}\" data-aria-posinset=\"2\" data-aria-level=\"1\">\n<h3><span data-contrast=\"auto\">Working with the state for a power purchase agreement to offset remaining energy usage, long-term investment plan to expand roof solar panels.\u00a0<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/h3>\n<\/li>\n<\/ul>\n<ul>\n<li data-leveltext=\"\uf0b7\" data-font=\"Symbol\" data-listid=\"3\" data-list-defn-props=\"{&quot;335552541&quot;:1,&quot;335559685&quot;:720,&quot;335559991&quot;:360,&quot;469769226&quot;:&quot;Symbol&quot;,&quot;469769242&quot;:[8226],&quot;469777803&quot;:&quot;left&quot;,&quot;469777804&quot;:&quot;\uf0b7&quot;,&quot;469777815&quot;:&quot;hybridMultilevel&quot;}\" data-aria-posinset=\"3\" data-aria-level=\"1\">\n<h3><span data-contrast=\"auto\">More robust insulation on the roof and insulated panels for better climate controls <\/span><span data-contrast=\"auto\">and insulated panels.<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/h3>\n<\/li>\n<\/ul>\n<ul>\n<li data-leveltext=\"\uf0b7\" data-font=\"Symbol\" data-listid=\"3\" data-list-defn-props=\"{&quot;335552541&quot;:1,&quot;335559685&quot;:720,&quot;335559991&quot;:360,&quot;469769226&quot;:&quot;Symbol&quot;,&quot;469769242&quot;:[8226],&quot;469777803&quot;:&quot;left&quot;,&quot;469777804&quot;:&quot;\uf0b7&quot;,&quot;469777815&quot;:&quot;hybridMultilevel&quot;}\" data-aria-posinset=\"4\" data-aria-level=\"1\">\n<h3><span data-contrast=\"auto\">Office furniture was 100% reused and refurbished.<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/h3>\n<\/li>\n<\/ul>\n<ul>\n<li data-leveltext=\"\uf0b7\" data-font=\"Symbol\" data-listid=\"3\" data-list-defn-props=\"{&quot;335552541&quot;:1,&quot;335559685&quot;:720,&quot;335559991&quot;:360,&quot;469769226&quot;:&quot;Symbol&quot;,&quot;469769242&quot;:[8226],&quot;469777803&quot;:&quot;left&quot;,&quot;469777804&quot;:&quot;\uf0b7&quot;,&quot;469777815&quot;:&quot;hybridMultilevel&quot;}\" data-aria-posinset=\"5\" data-aria-level=\"1\">\n<h3><span data-contrast=\"auto\">Solar panel installation on the roof assists with energy supply to the building<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/h3>\n<\/li>\n<\/ul>\n<ul>\n<li data-leveltext=\"\uf0b7\" data-font=\"Symbol\" data-listid=\"3\" data-list-defn-props=\"{&quot;335552541&quot;:1,&quot;335559685&quot;:720,&quot;335559991&quot;:360,&quot;469769226&quot;:&quot;Symbol&quot;,&quot;469769242&quot;:[8226],&quot;469777803&quot;:&quot;left&quot;,&quot;469777804&quot;:&quot;\uf0b7&quot;,&quot;469777815&quot;:&quot;hybridMultilevel&quot;}\" data-aria-posinset=\"6\" data-aria-level=\"1\">\n<h3><span data-contrast=\"auto\">Generator backup for the facility is a biodiesel generator used for critical emergency backup.\u00a0<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/h3>\n<\/li>\n<\/ul>\n<ul>\n<li data-leveltext=\"\uf0b7\" data-font=\"Symbol\" data-listid=\"3\" data-list-defn-props=\"{&quot;335552541&quot;:1,&quot;335559685&quot;:720,&quot;335559991&quot;:360,&quot;469769226&quot;:&quot;Symbol&quot;,&quot;469769242&quot;:[8226],&quot;469777803&quot;:&quot;left&quot;,&quot;469777804&quot;:&quot;\uf0b7&quot;,&quot;469777815&quot;:&quot;hybridMultilevel&quot;}\" data-aria-posinset=\"7\" data-aria-level=\"1\">\n<h3><span data-contrast=\"auto\">Geothermal heating and cooling, with ABB\u2019s BMS to control the heating and cooling of the facility.<\/span><\/h3>\n<\/li>\n<\/ul>\n<p><iframe loading=\"lazy\" title=\"ABB new facility: Electrical safety\" width=\"500\" height=\"281\" src=\"https:\/\/www.youtube.com\/embed\/y9suy2uwOLw?feature=oembed\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share\" referrerpolicy=\"strict-origin-when-cross-origin\" allowfullscreen><\/iframe><\/p>\n<p><span data-contrast=\"auto\">During the presentation, Hoysniemi added that sustainability is part of ABB\u2019s daily work, part of the company\u2019s DNA and the value ABB provides. \u201cIt\u2019s often said that achieving sustainability goals requires compromises and higher costs. That\u2019s not so. There\u2019s no increase in cost,\u201d Hoysniemi said. \u201cWe\u2019re demonstrating and enabling a low-carbon society, helping customers to decarbonize. This is made to showcase to customers how it can be done.\u201d<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/p>\n<figure id=\"attachment_548229\" aria-describedby=\"caption-attachment-548229\" style=\"width: 1020px\" class=\"wp-caption alignnone\"><img loading=\"lazy\" decoding=\"async\" class=\"wp-image-548229 size-full\" src=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/01\/CTL2411_WEB_ABB-New-Berlin-Fig8-Fieldbus-connectivity-mHoske-scaled-e1736204306525-1.jpg\" alt=\"The new ABB drives and services manufacturing and logistics center, New Berlin, Wisconsin, includes a fieldbus connectivity area, said Jeff Fell, application engineering manager, including areas for building automation controller communication, industrial programmable logic controller (PLC) network protocols and industrial PLC network safety protocols. Courtesy: Mark T. Hoske, Control Engineering, WTWH Media\" width=\"1020\" height=\"765\" \/><figcaption id=\"caption-attachment-548229\" class=\"wp-caption-text\">The new ABB drives and services manufacturing and logistics center, New Berlin, Wisconsin, includes a fieldbus connectivity area, said Jeff Fell, application engineering manager, including areas for building automation controller communication, industrial programmable logic controller (PLC) network protocols and industrial PLC network safety protocols. Courtesy: Mark T. Hoske, Control Engineering, WTWH Media<\/figcaption><\/figure>\n<p><span data-contrast=\"auto\">Rep. Scott Fitzgerald, U.S. Congressman, Wisconsin \u2013 5th District, said many corporations that hit the pause button during the pandemic have changed to investments. ABB has been in Southeast Wisconsin for decades, he said. Wisconsin is known for manufacturing, tourism and agriculture, and has tool and die manufacturers for light manufacturing support, including the technical colleges needed to continue to feed manufacturers in the state, he said.<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/p>\n<h2><span data-contrast=\"auto\">HVACR tour details: High efficiency technologies help facility sustainability, decarbonization<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/h2>\n<p><span data-contrast=\"auto\">Decarbonization and sustainability details were provided by Tim Skell, ABB global HVACR application engineering manager (HVACR stands for heating, ventilation, air conditioning, refrigeration). Skell said older facility mechanical rooms are dark, dingy and hidden away. This one was designed to showcase advanced energy efficient sustainability technologies.<\/span><\/p>\n<figure id=\"attachment_548230\" aria-describedby=\"caption-attachment-548230\" style=\"width: 765px\" class=\"wp-caption alignnone\"><img loading=\"lazy\" decoding=\"async\" class=\"wp-image-548230 size-full\" src=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/01\/CTL2411_WEB_ABB-New-Berlin-Fig9-Jeff-Fell-panel-safety-mHoske-scaled-e1736204332402-1.jpg\" alt=\"Electrical panel safety integrated into the ABB New Berlin, Wisconsin, training area has arc flash protection. LED indicators show what receptacle is hot and if a fuse inside the panel has blown, said Jeff Fell, ABB application engineering manager. Courtesy: Mark T. Hoske, Control Engineering, WTWH Media\" width=\"765\" height=\"1020\" \/><figcaption id=\"caption-attachment-548230\" class=\"wp-caption-text\">Electrical panel safety integrated into the ABB New Berlin, Wisconsin, training area has arc flash protection. LED indicators show what receptacle is hot and if a fuse inside the panel has blown, said Jeff Fell, ABB application engineering manager. Courtesy: Mark T. Hoske, Control Engineering, WTWH Media<\/figcaption><\/figure>\n<h3><span data-contrast=\"auto\">Geothermal and mechanical room facts include the following.<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/h3>\n<ul>\n<li data-leveltext=\"\uf0b7\" data-font=\"Symbol\" data-listid=\"2\" data-list-defn-props=\"{&quot;335552541&quot;:1,&quot;335559685&quot;:720,&quot;335559991&quot;:360,&quot;469769226&quot;:&quot;Symbol&quot;,&quot;469769242&quot;:[8226],&quot;469777803&quot;:&quot;left&quot;,&quot;469777804&quot;:&quot;\uf0b7&quot;,&quot;469777815&quot;:&quot;hybridMultilevel&quot;}\" data-aria-posinset=\"1\" data-aria-level=\"1\">\n<h3><span data-contrast=\"auto\">Geothermal installation has 225 tons of capacity using 78 vertical wells, 500-feet deep.\u00a0<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/h3>\n<\/li>\n<\/ul>\n<ul>\n<li data-leveltext=\"\uf0b7\" data-font=\"Symbol\" data-listid=\"2\" data-list-defn-props=\"{&quot;335552541&quot;:1,&quot;335559685&quot;:720,&quot;335559991&quot;:360,&quot;469769226&quot;:&quot;Symbol&quot;,&quot;469769242&quot;:[8226],&quot;469777803&quot;:&quot;left&quot;,&quot;469777804&quot;:&quot;\uf0b7&quot;,&quot;469777815&quot;:&quot;hybridMultilevel&quot;}\" data-aria-posinset=\"2\" data-aria-level=\"1\">\n<h3><span data-contrast=\"auto\">Condenser water pumps to geothermal provide move up to 465 GPM at 30 HP.\u00a0<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/h3>\n<\/li>\n<\/ul>\n<ul>\n<li data-leveltext=\"\uf0b7\" data-font=\"Symbol\" data-listid=\"2\" data-list-defn-props=\"{&quot;335552541&quot;:1,&quot;335559685&quot;:720,&quot;335559991&quot;:360,&quot;469769226&quot;:&quot;Symbol&quot;,&quot;469769242&quot;:[8226],&quot;469777803&quot;:&quot;left&quot;,&quot;469777804&quot;:&quot;\uf0b7&quot;,&quot;469777815&quot;:&quot;hybridMultilevel&quot;}\" data-aria-posinset=\"3\" data-aria-level=\"1\">\n<h3><span data-contrast=\"auto\">Hot water pumps move up to 250 GPM at 15 HP.<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/h3>\n<\/li>\n<\/ul>\n<ul>\n<li data-leveltext=\"\uf0b7\" data-font=\"Symbol\" data-listid=\"2\" data-list-defn-props=\"{&quot;335552541&quot;:1,&quot;335559685&quot;:720,&quot;335559991&quot;:360,&quot;469769226&quot;:&quot;Symbol&quot;,&quot;469769242&quot;:[8226],&quot;469777803&quot;:&quot;left&quot;,&quot;469777804&quot;:&quot;\uf0b7&quot;,&quot;469777815&quot;:&quot;hybridMultilevel&quot;}\" data-aria-posinset=\"4\" data-aria-level=\"1\">\n<h3><span data-contrast=\"auto\">Chilled water pumps move up to 305 GPM at 7.5 HP.<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/h3>\n<\/li>\n<\/ul>\n<ul>\n<li data-leveltext=\"\uf0b7\" data-font=\"Symbol\" data-listid=\"2\" data-list-defn-props=\"{&quot;335552541&quot;:1,&quot;335559685&quot;:720,&quot;335559991&quot;:360,&quot;469769226&quot;:&quot;Symbol&quot;,&quot;469769242&quot;:[8226],&quot;469777803&quot;:&quot;left&quot;,&quot;469777804&quot;:&quot;\uf0b7&quot;,&quot;469777815&quot;:&quot;hybridMultilevel&quot;}\" data-aria-posinset=\"5\" data-aria-level=\"1\">\n<h3><span data-contrast=\"auto\">Air handler moves 60,000 CFM in a 12-fan array, using 10 HP motors, 120 HP total. Each motor has its own ABB ACH580 drive to control it.<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/h3>\n<\/li>\n<\/ul>\n<figure id=\"attachment_548231\" aria-describedby=\"caption-attachment-548231\" style=\"width: 1020px\" class=\"wp-caption alignnone\"><img loading=\"lazy\" decoding=\"async\" class=\"wp-image-548231 size-full\" src=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/01\/CTL2411_WEB_ABB-New-Berlin-Fig10-mechanical-room-geothermal-mHoske-scaled-e1736204364641-1.jpg\" alt=\"The ABB New Berlin, Wisconsin, facility geothermal heat-pump installation has 225 tons of capacity using 78 vertical wells, 500-feet deep, said Tim Skell, ABB global HVACR application engineering manager (HVACR stands for heating, ventilation, air conditioning, refrigeration). Courtesy: Mark T. Hoske, Control Engineering, WTWH Media\" width=\"1020\" height=\"765\" \/><figcaption id=\"caption-attachment-548231\" class=\"wp-caption-text\">The ABB New Berlin, Wisconsin, facility geothermal heat-pump installation has 225 tons of capacity using 78 vertical wells, 500-feet deep, said Tim Skell, ABB global HVACR application engineering manager (HVACR stands for heating, ventilation, air conditioning, refrigeration). Courtesy: Mark T. Hoske, Control Engineering, WTWH Media<\/figcaption><\/figure>\n<ul>\n<li data-leveltext=\"\uf0b7\" data-font=\"Symbol\" data-listid=\"2\" data-list-defn-props=\"{&quot;335552541&quot;:1,&quot;335559685&quot;:720,&quot;335559991&quot;:360,&quot;469769226&quot;:&quot;Symbol&quot;,&quot;469769242&quot;:[8226],&quot;469777803&quot;:&quot;left&quot;,&quot;469777804&quot;:&quot;\uf0b7&quot;,&quot;469777815&quot;:&quot;hybridMultilevel&quot;}\" data-aria-posinset=\"6\" data-aria-level=\"1\">\n<h3><span data-contrast=\"auto\">Motors technology: Ferrite-assisted synchronous reluctance (FASR) motors are extremely efficient, Skell explained. While they essentially mean the same thing as a permanent magnet synchronous reluctance motor from a motor theory standpoint, Skell said, the \u201cpermanent magnet\u201d phrase also can imply \u201crare earth\u201d magnets with some interpretations. For sustainability reasons, the motor design intentionally avoids using rare earth style magnets, instead using typical ferrite magnets, so the official term for the motor is ferrite-assisted synchronous reluctance or FASR. The site uses the version with a separate variable frequency drive (VFD), rather than integrated motor and drive. ABB explains more about the <\/span><a href=\"https:\/\/www.baldor.com\/mvc\/DownloadCenter\/Files\/BR493\" target=\"_blank\" rel=\"noopener\"><span data-contrast=\"none\">Baldor-Reliance EC Titanium motors and integrated drives<\/span><\/a><span data-contrast=\"auto\">.<\/span><\/h3>\n<\/li>\n<\/ul>\n<ul>\n<li data-leveltext=\"\uf0b7\" data-font=\"Symbol\" data-listid=\"2\" data-list-defn-props=\"{&quot;335552541&quot;:1,&quot;335559685&quot;:720,&quot;335559991&quot;:360,&quot;469769226&quot;:&quot;Symbol&quot;,&quot;469769242&quot;:[8226],&quot;469777803&quot;:&quot;left&quot;,&quot;469777804&quot;:&quot;\uf0b7&quot;,&quot;469777815&quot;:&quot;hybridMultilevel&quot;}\" data-aria-posinset=\"7\" data-aria-level=\"1\">\n<h3><span data-contrast=\"auto\">Heat pump (6-pipe heat recovery chiller) is rated at 150 tons (six 25-ton stages).<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/h3>\n<\/li>\n<\/ul>\n<ul>\n<li data-leveltext=\"\uf0b7\" data-font=\"Symbol\" data-listid=\"2\" data-list-defn-props=\"{&quot;335552541&quot;:1,&quot;335559685&quot;:720,&quot;335559991&quot;:360,&quot;469769226&quot;:&quot;Symbol&quot;,&quot;469769242&quot;:[8226],&quot;469777803&quot;:&quot;left&quot;,&quot;469777804&quot;:&quot;\uf0b7&quot;,&quot;469777815&quot;:&quot;hybridMultilevel&quot;}\" data-aria-posinset=\"8\" data-aria-level=\"1\">\n<h3><span data-contrast=\"auto\">The VFDs mixed ABB ACH580 packaged solutions, with and without bypass (Bypass allows motor function without the drive, should a drive fail) and a redundant drive.<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/h3>\n<\/li>\n<\/ul>\n<ul>\n<li data-leveltext=\"\uf0b7\" data-font=\"Symbol\" data-listid=\"2\" data-list-defn-props=\"{&quot;335552541&quot;:1,&quot;335559685&quot;:720,&quot;335559991&quot;:360,&quot;469769226&quot;:&quot;Symbol&quot;,&quot;469769242&quot;:[8226],&quot;469777803&quot;:&quot;left&quot;,&quot;469777804&quot;:&quot;\uf0b7&quot;,&quot;469777815&quot;:&quot;hybridMultilevel&quot;}\" data-aria-posinset=\"9\" data-aria-level=\"1\">\n<h3><span data-contrast=\"auto\">Enclosures: Type 1, Type 12, Type 3R and Type NEMA 4X enclosures.<\/span><\/h3>\n<\/li>\n<\/ul>\n<ul>\n<li data-leveltext=\"\uf0b7\" data-font=\"Symbol\" data-listid=\"2\" data-list-defn-props=\"{&quot;335552541&quot;:1,&quot;335559685&quot;:720,&quot;335559991&quot;:360,&quot;469769226&quot;:&quot;Symbol&quot;,&quot;469769242&quot;:[8226],&quot;469777803&quot;:&quot;left&quot;,&quot;469777804&quot;:&quot;\uf0b7&quot;,&quot;469777815&quot;:&quot;hybridMultilevel&quot;}\" data-aria-posinset=\"10\" data-aria-level=\"1\">\n<h3><span data-contrast=\"auto\">Drive technologies: 6-pulse (ACS320 drive, the only one that wasn\u2019t an ACH580 family), 6-pulse with 5% equivalent impedance, and ultra-low harmonic active front end (AFE) drives to ensure high power quality in connected systems. (Harmonic disturbances, or electrical noise, can harm some devices and processes, and some utilities charge industrial companies extra fees if harmonic disturbances are introduced locally.)<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/h3>\n<\/li>\n<\/ul>\n<ul>\n<li data-leveltext=\"\uf0b7\" data-font=\"Symbol\" data-listid=\"2\" data-list-defn-props=\"{&quot;335552541&quot;:1,&quot;335559685&quot;:720,&quot;335559991&quot;:360,&quot;469769226&quot;:&quot;Symbol&quot;,&quot;469769242&quot;:[8226],&quot;469777803&quot;:&quot;left&quot;,&quot;469777804&quot;:&quot;\uf0b7&quot;,&quot;469777815&quot;:&quot;hybridMultilevel&quot;}\" data-aria-posinset=\"11\" data-aria-level=\"1\">\n<h3><span data-contrast=\"auto\">The controls use ABB Smart Building Solutions. All the controls, thermostats and future AI implementation will all be ABB products. A big six-screen operator workstation is expected to be installed within the next month or two, with graphics, trending and sub-metering to identify power usage.<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/h3>\n<\/li>\n<\/ul>\n<p><iframe loading=\"lazy\" title=\"ABB new facility: Brightened mechanical rooms\" width=\"500\" height=\"281\" src=\"https:\/\/www.youtube.com\/embed\/pmP9PTki_Eo?feature=oembed\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share\" referrerpolicy=\"strict-origin-when-cross-origin\" allowfullscreen><\/iframe><\/p>\n<h2><span data-contrast=\"auto\">ABB VFD manufacturing design innovations, 7 smart factory attributes<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/h2>\n<figure id=\"attachment_548233\" aria-describedby=\"caption-attachment-548233\" style=\"width: 765px\" class=\"wp-caption alignnone\"><img loading=\"lazy\" decoding=\"async\" class=\"wp-image-548233 size-full\" src=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/01\/CTL2411_WEB_ABB-New-Berlin-Fig12-mechanical-room-geothermal-12-VFDs-mHoske-scaled-e1736204408788-1.jpg\" alt=\"The ABB New Berlin, Wisconsin, facility air handler moves 60,000 CFM in a 12-fan array, using 10 HP motors, 120 HP total. Each motor has its own ABB ACH580 drive to control it, said Tim Skell, ABB global HVACR application engineering manager (HVACR stands for heating, ventilation, air conditioning, refrigeration). The air handler uses extremely efficient ferrite-assisted synchronous reluctance (FASR) motors, he said. Courtesy: Mark T. Hoske, Control Engineering, WTWH Media\" width=\"765\" height=\"1020\" \/><figcaption id=\"caption-attachment-548233\" class=\"wp-caption-text\">The ABB New Berlin, Wisconsin, facility air handler moves 60,000 CFM in a 12-fan array, using 10 HP motors, 120 HP total. Each motor has its own ABB ACH580 drive to control it, said Tim Skell, ABB global HVACR application engineering manager (HVACR stands for heating, ventilation, air conditioning, refrigeration). The air handler uses extremely efficient ferrite-assisted synchronous reluctance (FASR) motors, he said. Courtesy: Mark T. Hoske, Control Engineering, WTWH Media<\/figcaption><\/figure>\n<h3><span data-contrast=\"auto\">About ABB\u2019s New Berlin drive manufacturing (no photos were allowed) Daniel Beaudet, director quality \u2013 advanced manufacturing, continuous improvement, U.S. motion business, said ABB worked with Porche Consulting on seven attributes of this smart factory of the future:<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/h3>\n<ol>\n<li>\n<h3><span data-contrast=\"auto\"> Adaptable and scalable to handle demand variability and meet customer lead times.<\/span><\/h3>\n<\/li>\n<li>\n<h3><span data-contrast=\"auto\"> Attractive, creating operator engagement and demonstrating net zero carbon emission sustainability goals.<\/span><\/h3>\n<\/li>\n<li>\n<h3><span data-contrast=\"auto\"> Lean material and information flow, improving connections to suppliers and customers.<\/span><\/h3>\n<\/li>\n<li>\n<h3><span data-contrast=\"auto\"> External customer focus with on-time delivery and improved communication and feedback with greater information transparency.<\/span><\/h3>\n<\/li>\n<li>\n<h3><span data-contrast=\"auto\"> Lean and robust processes to mitigate issues earlier and lessen impact to assembly lines with quality, standards, early abnormality detection and error proofing.<\/span><\/h3>\n<\/li>\n<li>\n<h3><span data-contrast=\"auto\"> Smart and data driven systems with interoperable systems, modeling, simulation, intelligent automation, strong cybersecurity and networked sensors.<\/span><\/h3>\n<\/li>\n<li>\n<h3><span data-contrast=\"auto\"> Top quality enabled by integrated systems throughout the value system.<\/span><\/h3>\n<\/li>\n<\/ol>\n<figure id=\"attachment_548234\" aria-describedby=\"caption-attachment-548234\" style=\"width: 765px\" class=\"wp-caption alignnone\"><img loading=\"lazy\" decoding=\"async\" class=\"wp-image-548234 size-full\" src=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/01\/CTL2411_WEB_ABB-New-Berlin-Fig13-mechanical-room-geothermal-condenser-pumps-mHoske-scaled-e1736204557792-1.jpg\" alt=\"In the ABB New Berlin, Wisconsin, mechanical room, condenser water pumps to the geothermal system move up to 465 GPM at 30 HP, said Tim Skell, ABB global HVACR application engineering manager (HVACR stands for heating, ventilation, air conditioning, refrigeration). Courtesy: Mark T. Hoske, Control Engineering, WTWH Media\" width=\"765\" height=\"1020\" \/><figcaption id=\"caption-attachment-548234\" class=\"wp-caption-text\">In the ABB New Berlin, Wisconsin, mechanical room, condenser water pumps to the geothermal system move up to 465 GPM at 30 HP, said Tim Skell, ABB global HVACR application engineering manager (HVACR stands for heating, ventilation, air conditioning, refrigeration). Courtesy: Mark T. Hoske, Control Engineering, WTWH Media<\/figcaption><\/figure>\n<h2><span data-contrast=\"auto\">Adjustable workstations, multiple VFD models on same line, ABB products throughout<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/h2>\n<p><span data-contrast=\"auto\">In planning since 2021, the factory has standardized touchscreens for every work area, Beaudet said, so workers can learn one area and <\/span><span data-contrast=\"auto\">be able to<\/span><span data-contrast=\"auto\"> work in all areas. Built-in ergonometric design adjusts the workstation to fit the worker when securely \u201ccarding into\u201d each station.<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/p>\n<p><iframe loading=\"lazy\" title=\"ABB new facilities: Variable frequency drive\" width=\"500\" height=\"281\" src=\"https:\/\/www.youtube.com\/embed\/CSaIOjgxZic?feature=oembed\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share\" referrerpolicy=\"strict-origin-when-cross-origin\" allowfullscreen><\/iframe><\/p>\n<p><span data-contrast=\"auto\">ABB New Berlin factory layout is displayed on a large screen monitor with a Lego representation below, appealing to all ages of those touring the manufacturing area.\u00a0<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/p>\n<p><span data-contrast=\"auto\">At the time of the tour, pilot manufacturing running in the plant were validating manufacturing workflow, production and testing of five ABB VFDs, Beaudet said, with capabilities to run multiple design and customer variations on each line.\u00a0<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/p>\n<figure id=\"attachment_548221\" aria-describedby=\"caption-attachment-548221\" style=\"width: 1920px\" class=\"wp-caption alignnone\"><img loading=\"lazy\" decoding=\"async\" class=\"wp-image-548221 size-full\" src=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/01\/CTL2411_WEB_ABB-New-Berlin-Fig14-mechanical-room-Tim-Skell-VFD-redundancy-bypass-mHoske-scaled-1.jpg\" alt=\"Tim Skell, ABB global HVACR application engineering manager (HVACR stands for heating, ventilation, air conditioning, refrigeration), explains how ABB variable frequency drives (VFDs) are configured with redundancy or bypass for various design risk scenarios to fit different applications and facilities, part of the ABB New Berlin, Wisconsin, mechanical room tour. Courtesy: Mark T. Hoske, Control Engineering, WTWH Media \" width=\"1920\" height=\"2560\" \/><figcaption id=\"caption-attachment-548221\" class=\"wp-caption-text\">Tim Skell, ABB global HVACR application engineering manager (HVACR stands for heating, ventilation, air conditioning, refrigeration), explains how ABB variable frequency drives (VFDs) are configured with redundancy or bypass for various design risk scenarios to fit different applications and facilities, part of the ABB New Berlin, Wisconsin, mechanical room tour. Courtesy: Mark T. Hoske, Control Engineering, WTWH Media<\/figcaption><\/figure>\n<p><span data-contrast=\"auto\">He explained how an ABB robot performs laser marking, providing a \u201cbirth certificate\u201d for each drive.\u00a0<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/p>\n<p><span data-contrast=\"auto\">Automated guided vehicles (AGVs) are planned for efficient material flow in the plant.\u00a0<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/p>\n<p><span data-contrast=\"auto\">ABB equipment is used throughout to help make more ABB products. In a few cases, Beaudet said, ABB worked with original equipment manufacturers to ensure ABB products were used in machines used in New Berlin manufacturing processes.<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/p>\n<figure id=\"attachment_548235\" aria-describedby=\"caption-attachment-548235\" style=\"width: 765px\" class=\"wp-caption alignnone\"><img loading=\"lazy\" decoding=\"async\" class=\"wp-image-548235 size-full\" src=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/01\/CTL2411_WEB_ABB-New-Berlin-Fig16-mechanical-room-chilled-water-pump-mHoske-scaled-e1736204852133-1.jpg\" alt=\"In the ABB New Berlin, Wisconsin, mechanical room, a pair of chilled water pumps provide N+1 redundancy, said Tim Skell, ABB global HVACR application engineering manager (HVACR stands for heating, ventilation, air conditioning, refrigeration).\" width=\"765\" height=\"1020\" \/><figcaption id=\"caption-attachment-548235\" class=\"wp-caption-text\">In the ABB New Berlin, Wisconsin, mechanical room, a pair of chilled water pumps provide N+1 redundancy, said Tim Skell, ABB global HVACR application engineering manager (HVACR stands for heating, ventilation, air conditioning, refrigeration).<\/figcaption><\/figure>\n<h2><span data-contrast=\"auto\">Classroom and hands-on electrical, safety, mechatronics education<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/h2>\n<p><span data-contrast=\"auto\">Jeff Fell, application engineering manager, highlighted multiple classroom and lab training areas, showing 14 workstations, up from six in the prior facility. Drive harmonics, among areas of instruction, include an advanced demonstration area with third-generation AFE VFD technology for better electrical noise mitigation to improve power quality.<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/p>\n<figure id=\"attachment_548236\" aria-describedby=\"caption-attachment-548236\" style=\"width: 765px\" class=\"wp-caption alignnone\"><img loading=\"lazy\" decoding=\"async\" class=\"wp-image-548236 size-full\" src=\"https:\/\/www.controleng.com\/wp-content\/uploads\/2025\/01\/CTL2411_WEB_ABB-New-Berlin-Fig15-mechanical-room-geothermal-pumps-mHoske-scaled-e1736205108569-1.jpg\" alt=\"Pumps for hot water return (orange pipes) move up to 250 GPM at 15 HP, part of the ABB New Berlin, Wisconsin, geothermal design, said Tim Skell, ABB global HVACR application engineering manager (HVACR stands for heating, ventilation, air conditioning, refrigeration). Courtesy: Mark T. Hoske, Control Engineering, WTWH Media \" width=\"765\" height=\"1020\" \/><figcaption id=\"caption-attachment-548236\" class=\"wp-caption-text\">Pumps for hot water return (orange pipes) move up to 250 GPM at 15 HP, part of the ABB New Berlin, Wisconsin, geothermal design, said Tim Skell, ABB global HVACR application engineering manager (HVACR stands for heating, ventilation, air conditioning, refrigeration). Courtesy: Mark T. Hoske, Control Engineering, WTWH Media<\/figcaption><\/figure>\n<p><span data-contrast=\"auto\">In another demonstration, Fell showed how a drive adjusts flow to avoid creating air (cavitation) inside liquid flow, which can prevent product spoilage and decrease maintenance (<a href=\"https:\/\/www.youtube.com\/shorts\/ih5K7DEay-g\" target=\"_blank\" rel=\"noopener\">see video<\/a>).<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/p>\n<p><span data-contrast=\"auto\">A dynameter lab provides advanced motor and drive design and application testing, including simulation of loads that water would make in pumping applications, without using water (<a href=\"https:\/\/www.youtube.com\/shorts\/4l8kqT292S8\" target=\"_blank\" rel=\"noopener\">video<\/a>).<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/p>\n<p><span data-contrast=\"auto\">CONSIDER THIS<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/p>\n<p><span data-contrast=\"auto\">How are motors and drives contributing to sustainability, efficiency, quality and cost-saving goals?<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/p>\n<p><span data-contrast=\"auto\">ONLINE<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/p>\n<p><span data-contrast=\"auto\">Online version of this article expands the November\/December <\/span><i><span data-contrast=\"auto\">Control Engineering<\/span><\/i><span data-contrast=\"auto\"> in-print summary with 16 images, five video clips and more text with site details.<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/p>\n<p><span data-contrast=\"auto\">Three ABB executives wrote recent <\/span><i><span data-contrast=\"auto\">Control Engineering<\/span><\/i><span data-contrast=\"auto\"> sustainability articles about motors, drives and electrification.<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/p>\n<p><span data-contrast=\"auto\">Benjamin Hinds, vice president of product management and marketing at the NEMA Motors:<a href=\"https:\/\/www.controleng.com\/articles\/how-to-meet-sustainability-goals-part-1-high-efficiency-motors\" target=\"_blank\" rel=\"noopener\"> \u201cHow to meet sustainability goals, part 1: High-efficiency motors.\u201d<\/a><\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/p>\n<p><span data-contrast=\"auto\">Michael Basler, local division manager for the System Drives Division at ABB in the United States: <a href=\"https:\/\/www.controleng.com\/articles\/how-to-meet-sustainability-goals-part-2-the-drive-for-industrial-decarbonization\" target=\"_blank\" rel=\"noopener\">\u201cHow to meet sustainability goals, part 2: The drive for industrial decarbonization.\u201d<\/a><\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/p>\n<p><span data-contrast=\"auto\">Rob Snyder, local division manager, ABB U.S. Motion Services Division: <a href=\"https:\/\/www.controleng.com\/articles\/how-to-meet-sustainability-goals-part-3-examining-roles-of-motion-services\" target=\"_blank\" rel=\"noopener\">\u201cHow to meet sustainability goals, part 3: Examining roles of motion services.\u201d<\/a><\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/p>\n<p><span data-contrast=\"auto\">An extended video interview with Hinds, Basler and Snyder explains more about motor, drive and electrification technologies and sustainability: <a href=\"https:\/\/www.youtube.com\/watch?v=QVkw4x4dMGE\" target=\"_blank\" rel=\"noopener\">\u201cExpert video interview: Three ways motors and drives help industrial sustainability.\u201d<\/a>\u00a0<\/span><\/p>\n<p><a href=\"https:\/\/new.abb.com\/service\/abb-university\/united-states\/drives\/us-training\/new-berlin-wi-training-center\" target=\"_blank\" rel=\"noopener\"><span data-contrast=\"auto\">ABB provides training information for the New Berlin site.\u00a0<\/span><\/a><\/p>\n","protected":false},"excerpt":{"rendered":"<p>&nbsp; Learning Objectives Understand six benefits to automated, advanced manufacturing and warehousing facility, seven smart factory attributes. Learn about new automated manufacturing, educational labs, sustainability methods. Explore a $100 million automated, advanced manufacturing and motor, VFD and electrical training facility. Automated smart manufacturing, net zero facility and motor-VFD training insights\u00a0 Six benefits to a new [&hellip;]<\/p>\n","protected":false},"author":56,"featured_media":128617,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"pgc_sgb_lightbox_settings":"","footnotes":""},"categories":[109111,104047],"tags":[],"tracking-metrics":[],"display-location":[109353],"class_list":{"2":"type-post"},"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v25.9 - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>New facility: Six net zero benefits, seven smart manufacturing methods\u00a0 - Control Engineering<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.controleng.com\/new-facility-six-net-zero-benefits-seven-smart-manufacturing-methods\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"New facility: Six net zero benefits, seven smart manufacturing methods\u00a0 - Control Engineering\" \/>\n<meta property=\"og:description\" content=\"&nbsp; Learning Objectives Understand six benefits to automated, advanced manufacturing and warehousing facility, seven smart factory attributes. 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