While the broader energy initiative successfully delivered both energy savings and operational improvements, it was the new cooling towers—ironically, the original catalyst for the project—that emerged as a surprisingly large contributor to the hospital’s ongoing power savings.

Operating with Efficiency

“Originally, the owners wanted to go with an engineered plastic cooling tower because they liked the fact that it was corrosion-proof, required far less upkeep, and came with a 20-year warranty,” said David Buie, an account manager in controls sales at Powers, who helped kick off the project.

Based in North Little Rock, Arkansas, Powers is an HVAC, controls, and service company that partnered with the hospital to upgrade its cooling towers. However, as the project progressed, hospital leadership decided to broaden its scope to include a comprehensive review and optimization of the entire mechanical system.

To guide the expanded initiative, the hospital brought in an independent energy-efficiency engineering firm, which required competitive bidding for the new cooling towers. The final decision came down to two material options: high-density polyethylene (HDPE) engineered plastic and stainless steel.

“Once the engineering company saw the energy that could be saved by utilizing the HDPE towers, there was really no looking back,” Buie said.

A Healthier Bottom Line

Engineered plastic cooling towers were first pioneered by Delta Cooling Towers in the 1970s, and many of those original units remain in operation today. The energy savings delivered by these towers can be attributed to three key features: a modular design, multiple highly efficient motors and fans, and the use of variable-frequency drives (VFDs).

“Because of the way Delta’s towers are essentially separate cells that work together, the hospital can stage them down when they’re not all needed,” said Jared Hendrickson, Controls & Equipment Lead at Powers. “This can amount to huge savings on energy.”

Baptist Health Medical Center selected Delta’s TM Series, which consisted of 20 individual cells providing a total cooling capacity of 7,000 tons. The modular design allows for precise load management, and each unit is equipped with smaller 60-inch fans which significantly reduce energy consumption. Each cell contains two fans, all powered by VFDs that automatically reduce motor output when full fan speed isn’t required.

“When you operate the fan motors at 80% speed or less, you're saving about 50% on power,” Hendrickson said. “So, when you're talking about that much savings spread across 40 motors, the energy reduction is extensive.”

In addition to the superior turndown capabilities of the HDPE cooling towers, these units also feature much smaller motors – 15 horsepower (hp) compared to 150 hp in the stainless-steel alternative – further contributing to long-term savings.

Saving Energy and Improving Operations

In addition to reducing energy consumption, Baptist Health Medical Center has also significantly lowered maintenance costs. One key reason is the construction of the HDPE cooling towers, which feature a one-piece molded casing. The design eliminates joints and seams—common failure points in traditional towers that often lead to leaks and ongoing repair needs. The towers are also equipped with direct-drive fans, eliminating the need for gearboxes that require frequent maintenance and routine oil checks.

Additionally, while all cooling tower systems require chemical treatments to control algae, pathogens, and sediment buildup—all of which can hinder performance—the HDPE towers are immune to the corrosive effects of these chemicals.

“The chemical treatment is going to eat away at a metal tower, even a stainless tower, over time,” Hendrickson noted.

Installation time offers another advantage for contractors. HDPE systems can often be installed in just a day or two, compared to the multiple days, or even weeks, required for towers made from other materials.

“There are only two pieces held together by eight bolts,” explained Hendrickson. “Compare that to a thousand bolts and a thousand metal components on other towers. There's also no gasketing and caulking of panels before assembly. It’s a very simple installation process.”

A Clean Bill of (Energy) Health

Energy-efficiency measures don’t just reduce consumption; they can improve overall operations through optimized HVAC performance and smarter energy management. At Baptist Health Medical Center, the new cooling towers, installed at ground level, have also contributed to a quieter, more controlled medical environment.

Hospitals face unique challenges when it comes to energy use. Compliance with regulations like ASHRAE Standard 170 — which governs temperature, humidity, and air exchange rates — places constant pressure on facility executives, energy managers, and engineers to find sustainable, high-performance solutions.

Through careful selection of its cooling tower system and strategic mechanical upgrades, Baptist Health’s flagship facility achieved measurable, long-term power savings without compromising compliance or patient care.