Challenge
A leading custom control panel provider for the carwash industry faced significant challenges in maintaining operational efficiency for their customer’s carwash systems. These systems required precise control over conveyors, dryers, and spinning mops. Initially using ABB and Siemens drives, they struggled with long lead times and rising costs. Furthermore, they needed more durable, reliable, and energy-efficient Variable Frequency Drives (VFDs) to reduce downtime. Their customer, a large carwash chain with operations across the U.S. and Canada, needed efficient controls for various pieces of equipment.
Solution
Valin introduced Mitsubishi’s D700 Series VFDs to the customer in 2018. After reviewing the new VFDs, the customer recognized that Mitsubishi’s D700 Series would address the current issues they were facing. Initial testing on smaller projects led to a major shift in the company’s control systems. The customer initially placed orders for 15 VFDs (ranging from 2, 3, and 5 HP). The D700 Series offered a new architecture that allowed for smaller horsepower motors while maintaining consistent output, solving the customer’s immediate need for reliable performance and quicker availability compared to ABB and Siemens drives.
As the orders grew from dozens to hundreds, the customer began integrating Mitsubishi VFDs across various aspects of their production line, controlling critical equipment like conveyors, dryers, and spinning mops. Mitsubishi's VFDs were strategically positioned in their systems to manage the precise speed and direction of conveyor belts and auxiliary equipment.
The key to success was Mitsubishi’s ability to deliver durability and energy efficiency, even in demanding environments like carwashes. Their customer was impressed by the adaptability of the VFDs and the seamless installation process, making it an ideal solution for improving operational efficiency.
Benefits to the Customer
Reliability and Durability: Mitsubishi's D700 Series VFDs have proven highly reliable, with no warranty claims or component failures over the past several years. The robust design of the VFDs has made them well-suited for the rigorous demands of carwash environments, handling vibrations, temperature changes, and heavy-duty operations.
Energy Efficiency: Mitsubishi’s VFDs are designed for maximum energy efficiency, dynamically adjusting power consumption based on the load. This adaptability has led to significant energy savings for the carwash chain, contributing to their overall goal of sustainability and regulatory compliance. This energy-conscious design also reduces operational costs by optimizing power usage across the facility.
Lower Total Cost of Ownership (TCO): Mitsubishi’s VFDs come with a 5-year warranty and a 10-year maintenance-free design, significantly reducing the total cost of ownership. The combination of cost savings and reduced downtime has provided a substantial return on investment for the customer.
Seamless Scalability: As the carwash chain expanded, the customer continued to standardize Mitsubishi VFDs in their facilities. Mitsubishi’s flexibility allowed them to integrate the D700 Series across various systems, ensuring consistent control and performance as their operations scaled.
Sales Cycle
The sales cycle for this transformation began in late 2018 when the customer placed their first order for Mitsubishi D700 VFDs because that is what was available. Valin’s Sun Automation worked closely with the customer to demonstrate the value of Mitsubishi's solutions. Impressed with Mitsubishi’s reliability and cost-effectiveness, the President made the decision to integrate Mitsubishi VFDs across all projects, standardizing the product line moving forward.
Even during the COVID-19 pandemic, Mitsubishi VFDs proved critical to the carwash chain’s operations. Though supply chain issues briefly caused the customer to source cheaper drives from China, they returned to Mitsubishi in 2023 once supply stabilized, citing the unmatched reliability of the D700 Series. The customer continues to use Mitsubishi VFDs to this day.
Customer ROI and Savings
The customer experienced significant cost savings with Mitsubishi’s VFDs. Mitsubishi drives were more affordable than their previous ABB systems. The customer has placed nearly $200,000 worth of orders for Mitsubishi products in 2023 alone. Additionally, Mitsubishi’s lower long-term maintenance requirements and energy-efficient design resulted in reduced operational costs, further improving their return on investment.
Conclusion
The transition to Mitsubishi’s D700 Series VFDs has enabled the customer to overcome supply chain challenges, reduce downtime, and improve energy efficiency. The reliable performance and scalability of Mitsubishi VFDs have made them the preferred solution for their operations. With Valin’s support, the customer continues to grow and expand, placing Mitsubishi VFDs at the core of their carwash operations across the U.S. and Canada. Mitsubishi’s drives have proven critical to maintaining the efficiency, reliability, and profitability of the customer’s systems, securing their competitive position in the industry.