ECY Series Motor & Speed Controller for SKU Reduction and Cost Savings

Challenge

The customer needed to reduce the number of evaporator fan assembly SKUs they were purchasing due to increasing costs, complexity, and inventory risks. Because their equipment is designed and tested to meet specific performance and energy requirements, our solution had to be a drop-in replacement in terms of fit, form, and function.

EC Fans & Drives is a leading provider of EC motor technology for the commercial refrigeration markets in the U.S. and Europe. With extensive industry experience and a customer-focused approach, we collaborated closely with our clients to understand their needs. As a result, we not only met but exceeded expectations.

Solution

Using our in-house AMCA-approved wind tunnels, we conducted side-by-side airflow comparisons and successfully matched the customer’s current airflow performance with our EC fan solution. This ensured that the transition to our system would not compromise performance.

To support seamless integration, we designed and tooled a custom-molded plug and plastic fan ring, complete with all the required mounting holes and slot patterns. This design enabled a true drop-in replacement for each of the customer’s fan plenums, minimizing installation complexity.

For validation and pre-production testing, we supplied detailed 3D STP files along with rapid SLS prototype samples. This allowed the customer to confidently assess and approve the new design before moving forward.

By integrating our ECY global voltage fan assembly and speed controller into their production line, the customer now benefits from the ability to precisely adjust speed and airflow, delivering optimized performance across multiple operating conditions.

Result

By consolidating seven separate fan assembly SKUs into a single part number, the customer significantly streamlined their procurement and inventory management processes. This SKU reduction not only simplified internal operations but also provided immediate financial and logistical benefits.

One of the most notable outcomes was the reduction in inventory costs. By eliminating slow-moving SKUs that previously tied up capital and storage space, the customer freed up valuable resources that could be allocated elsewhere in their operation. This change also improved cash flow by accelerating inventory turnover and minimizing the risk of holding obsolete stock.

From a procurement and administrative standpoint, managing a single SKU dramatically reduced complexity. The simplified ordering process lowered administrative overhead and improved pricing through consolidated volume purchasing. Additionally, warehousing and logistics operations benefited from requiring less storage space and dealing with fewer SKU-related challenges.

Operationally, the customer gained greater flexibility and responsiveness. With a single, versatile fan assembly in use, they could react more quickly to shifts in production demand without the delays or complications associated with managing multiple part numbers.