Gurit composite materials support FridgeWize industrial chiller fan blades

FridgeWize (Shawnee, Kan., U.S.) a company that specializes in reducing energy in commercial refrigeration, uses composite blades for the motors of its walk-in refrigeration systems. In an effort to redesign and retool its carbon fiber blade production, FridgeWize was introduced to Gurit’s (Bristol, R.I., U.S.) line of products and technical support team.

FridgeWize retrofits high-efficiency motors — saving up to 70% of the energy costs associated with them. In the early stages of FridgeWize, it became apparent that the aluminum and plastic blades used in the evaporators of walk-in refrigeration systems were not optimized, were prone to plastic deformation causing imbalances, were relatively heavy and could suffer from fatigue. Consequently, FridgeWize improved blade design using carbon fiber which was not only lightweight but would not deform or become unbalanced.

Initially, these blades were manufactured for FridgeWize by third parties. However, as the manufacturers discontinued production, it paved the way for the launch of FridgeWize’s synergistic business, Advanced Carbon Fiber (ACF), in 2021.

ACF was formed to exclusively satisfy FridgeWize’s composite blade needs. This was also amidst a global shortage of carbon fiber, and a decision was made to redesign and retool the entire blade production for more efficient consumption of raw materials and to increase blade rigidity. Through local distributor Composites One based in Lenexa, Kan., U.S., ACF was introduced to Gurit.

With the assistance provided by Gurit’s team, guiding ACF’s process and manufacturing, ACF selected SE 180 prepreg for the fan blades, a hot in/hot out product suitable for use in presses. With the new design and materials, ACF is now able to produce a stronger, more efficient blade. The company has reported an increased output of 33% through design and cycle time reductions, while maintaining extreme quality control measures

Today, ACF is exceeding FridgeWize’s initial manufacturing demand, allowing for the launch of carbon fiber blades to others in the market who can benefit from this advanced technology.

Collaborating with Gurit has also solved many issues for ACF and FridgeWize. Gurit manufactures materials to customers’ specifications and preferred volumes. Its distributor has sizable freezer capacity, which enables the customer to receive materials as needed.

“The Gurit material is easier for us to work with,” Darren Traub, COO of ACF, says. “The mechanical precuring properties work better with our die cutters and preforms. The Gurit technical team is available and ready to help with any questions we have.”

In 2022, FridgeWize installed more than 25,000 fan blades made with Gurit’s composite materials.