The expansion added 82,000 square feet of manufacturing space, 20,000 square feet of office space, and 10,000 square feet of space for research and development laboratories.

“The $10.5-million expansion features production efficiencies that are already allowing for increased response to customer demands,” said Mark Hilton, Fulton Cos. vice president of manufacturing. “The new facility will also provide the opportunity to expand Fulton’s product lines.”

The expansion’s manufacturing space is now fully functional. Office space transitions have begun and are expected to be complete in the first quarter of 2012. An additional $3.5 million will be spent to complete project interior and equipment needs.

A heating system for the office space features a 12-zone in-floor radiant hydronic system. When there is a need for heat in this space, waste heat from either the factory’s research and development facilities, or its manufacturing processes, is assessed and used.

The office space is divided into 43 zones with a state-of-the-art chilled beam system mounted in the ceilings to efficiently distribute cooling to the building occupants. Cooling towers are incorporated to manage the energy balance of the overall system. The system also has the potential to utilize gas absorption heat pumps and retention ponds as an energy source.

The expansion provided an opportunity for Fulton’s affiliate, Synex Controls (Pulaski, N.Y.), to integrate a custom energy management system. The control system centralizes and manages the facility’s heating, cooling, fresh air, humidification, and lighting systems. A web interface allows employees to interact on a personal level with the heating and cooling system to capture comfort preferences. System-wide real-time data is readily available via the Internet, and Synex plans to display the control data for visitors in the facility’s lobby area.

The equipment installation and the Synex control system have been designed to integrate evolving technology over time, with the goal of keeping the overall system modern.

“Not only is this a beautiful facility that demonstrates some of the most advanced technology available in the industry, it also positions Fulton well for the future,” said Kathy Sega, Fulton Cos. executive vice president and general manager for U.S. operations.

Publication date: 01/30/2012