StoreMechanical services case study · Mount Laurel, New Jersey
NFL Films Chiller Upgrade Improves Cooling Reliability and Reduces Electricity Use
At NFL Films’ approximately 200,000-square-foot studio complex, dependable cooling supports production spaces and a film vault maintained at 54°F. The Tustin Group stabilized the site after a major equipment failure and helped replace its aging chillers.
The challenge
The facility relied on two aging chillers, and reliable cooling was essential for both film preservation and studio production. A major failure reduced the site’s available cooling capacity by 60% as summer approached, creating an immediate operational risk.
The response
The Tustin Group installed a temporary chiller so the facility could maintain cooling while repair and replacement options were evaluated. The project ultimately replaced both older machines with two 450-ton Smardt chillers using oil-free centrifugal compressor technology. Tustin completed the associated piping and startup work.
A more resilient chiller configuration
Each new chiller used five Danfoss Turbocor compressors, for ten compressors across the two machines. The previous system had four compressors in total. According to the original case study, this reduced the share of total cooling capacity represented by any one compressor from 25% to 10%.
The chillers were connected to the building automation system for remote performance monitoring and diagnostics. The configuration also allowed one compressor to be evaluated or serviced while the other compressors on that machine continued operating.
Reported energy results
The original case study reports that monthly electricity consumption declined by 10–12% after the new chillers were installed. It also states that the complex had used approximately 11 million kWh per year with the previous equipment and was projected to use less than 10 million kWh in the year discussed.
These are historic, customer-reported results from the original project case study. They are not presented as guaranteed results for other facilities.
Rebate eligibility
The source states that the project was eligible for a rebate through New Jersey’s SmartStart Buildings program after equipment performance data and pre- and post-installation conditions were reviewed. The PDF does not identify a rebate amount or confirm an amount ultimately received.
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