Touring Bradford White’s Heat Pump Water Heater Factory Was a Dream Come True For This Efficiency Nerd

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The primary cease of my heat pump water heater tour across America was an unbelievable expertise that allowed me to see each step of how my favourite expertise is made. Quite a lot of magic occurs on the Bradford White manufacturing facility, from metallic sheets arriving on pallets to packaged cardboard packing containers leaving on vans with warmth pump water heaters inside and the whole lot in between.

In late August, I journeyed as much as Middleville, Michigan. Right here, Bradford White has been making thousands and thousands of water heaters for over a century. I like all warmth pump water heater manufacturers (and have hugged them all) and am enthusiastic about all the brand new producers that are entering into the market. However Bradford White has a particular place in my coronary heart. First, they’ve the one manufacturing facility making warmth pump water heaters in America. Second, they’re a union manufacturing facility, and all over the place I went, I noticed the pleasure and craftsmanship that goes into producing a terrific product from people who find themselves actually invested of their office.

I first met the Bradford White crew at their Worldwide Technical Excellence Middle (iTEC™). The coaching facility, adjoining to the manufacturing facility, is the place plumbers, contractors, wholesalers, and producers’ reps from throughout the US and world come to coach on all forms of residential and industrial water heating merchandise. Since I’m thinking about decarbonizing warmth pump water heaters, I used to be excited to see how Bradford teaches installers the way to set up, program, and troubleshoot them in houses throughout the nation.

Subsequent, we went to the precise manufacturing facility. I placed on ear and eye safety and steel-toed boots after which walked practically 3 miles over the 1.4 million sq. foot manufacturing facility trying out the whole warmth pump water heater course of. It was a dream come true.

I noticed hard-working folks and machines bending sheets of metal into the water heater tanks and jackets after which placing the enamel liner on the tanks to stop corrosion. I noticed refrigerant traces wrapped round water heater tanks to hold the nice and cozy refrigerant from the compressor that sits on the highest of the warmth pump water heater to the water heater tank itself.

I watched how the spray foam insulation will get injected into the water heater in order that it prevents warmth from escaping, which is why a water heater can preserve water scorching all day and solely lose a pair levels of warmth. I additionally obtained to see how Bradford White tanks are powdercoated with white paint in a really environment friendly course of, and I noticed how compressors have been placed on prime of tanks and married into one environment friendly unit. It was just a little mindblowing to see how a lot goes into making a machine that heats all of the water a house will want, extremely effectively.

Considered one of my massive takeaways from the tour was the standard management constructed into the whole water heater meeting course of. That is essential in making certain that warmth pump water heaters work nicely in prospects’ houses as soon as they depart the manufacturing facility. From testing water tanks twice to verify they don’t leak, to testing for refrigerant leaks, to an hour-long high quality management take a look at because the water heater leaves the manufacturing facility (the place I noticed one unit not cross and be taken out to be mounted), Bradford White’s HPWHs went via the trials earlier than leaving the manufacturing facility.

Warmth pump water heaters are nonetheless solely a small proportion of the market (although gross sales grew 35% in 2023) and I might see that actuality at Bradford White’s manufacturing facility, the place the fuel and electrical resistance water heaters had many extra models coming down their respective traces. However that is altering rapidly, and Bradford White and different producers say their warmth pump traces are able to accommodate all of the demand that’s being created as we search to impress and decarbonize water heating. I can’t wait to take a look at the manufacturing facility once more in 5 years to see how the warmth pump line has scaled.

All in all, my first go to to a warmth pump water heater manufacturing facility did nothing wanting knock my socks off. I obtained to look at the dedication and onerous work of tons of of women and men, and the numerous intricate processes that go into making the water heaters that may save our planet. An enormous due to Bradford White for internet hosting me on the manufacturing facility.

Try the video beneath of my tour of Bradford White’s manufacturing facility and interview with Gregg Holladay (the 2 of us doing just a little warmth pump boogie on the finish). My subsequent cease on my tour is Chicago, to see a industrial warmth pump water heater in motion heating water for a lot of flats directly.

My Tour Throughout America will lead as much as Heat Pump Water Heater Day, October 23the place we’ll have fun the game-changing decarbonizing expertise.