As Utz continues to grow, its facility needs are rapidly evolving. Utz is known for producing customized reusable plastic packaging solutions used in logistics, storage, manufacturing, and material handling environments. Within its own production facility, airflow, comfort, equipment performance, and uptime are all important to keeping operations moving.
The Challenge
VASEY recently supported Utz with a significant airflow improvement project designed to address comfort cooling needs in active production areas. Over time, Utz’s facility had expanded through multiple additions. As new building sections were added, original wall louvers that once brought fresh air into the plant became enclosed inside newer construction. This limited airflow in key production areas where manufacturing equipment also adds substantial heat.
The Solution
To help improve air movement and employee comfort, VASEY installed a high-volume rooftop fan system that included 18 fans: 12 exhaust fans and six supply fans. The system was designed to move air through the space while accounting for the specific needs of Utz’s production environment.
A key part of the project was controlling how air moved through the production areas. Rather than directing air across sensitive process equipment, the supply fans were positioned to move air down the center aisle. This approach helps pull air through the space while reducing the risk of condensation around production tools and equipment.
The installation also required careful planning because Utz operates around the clock. With three shifts and limited shutdown windows, VASEY had to coordinate work around active production schedules, rooftop access, equipment placement, and system startup.
One of the most visible parts of the project was a helicopter lift used to place the rooftop fan units. The lift required detailed coordination and communication to safely move equipment into position while helping minimize disruption to the facility.
VASEY also installed controls to support system performance. Each fan can be adjusted individually, and the system is designed to help maintain slight positive building pressure. If an overhead door is opened and left open, the fans can respond to changes in building pressure. The controls are also being integrated with the fire alarm system so the supply and exhaust fans respond appropriately during a fire alarm event.
As final electrical follow-up items are completed, VASEY continues to support system adjustments and controls integration. This ongoing coordination will help ensure the fan system operates as intended and supports reliable long-term performance.
Results and Impact
The impact was noticeable soon after the fans were started. Employees responded positively to the improved airflow, and the system has already made a measurable difference in the production environment. In addition to improving comfort, the added air movement has helped reduce a non-threatening haze near the ceiling, contributing to better overall conditions in the space.
The new fan installation also improves long-term serviceability. Existing fans were difficult to access because maintenance often had to be performed from inside the building and over production equipment. The new rooftop units are serviceable from the roof, making future maintenance safer, more practical, and less disruptive.
Conclusion
The airflow project builds on VASEY’s broader work with Utz, including mechanical and process-related support for chilled water systems used in the manufacturing process. Together, these projects reflect VASEY’s ability to support complex facility needs in active production environments.
From planning and installation to controls coordination and follow-up, VASEY’s work at Utz demonstrates the value of practical problem-solving, mechanical expertise, and careful coordination in helping customers maintain productive, comfortable, and efficient facilities.