Project Overview
In 2020, JDI Plastics, Four Star Tool, and Crystal Die & Mold relocated their manufacturing operations from Rolling Meadows to an approximately 27,000-square-foot, two-story facility in Palatine, Illinois.
The building, previously occupied by a testing laboratory, required extensive electrical modifications to accommodate the companies' manufacturing operations, equipment layouts, office areas, lighting, and new rooftop HVAC systems.
LH Block Electric was recommended to the owner by BR Design & Architecture, an architectural firm with which we have maintained a longstanding working relationship.
Our involvement began before the relocation, with a survey of the original Rolling Meadows manufacturing facility to evaluate existing electrical equipment and determine how it could be incorporated into the new location.
Evaluating & Reusing Existing Electrical Equipment
One of the project's primary challenges was determining how to effectively reuse existing electrical infrastructure while adapting the Palatine building to its new manufacturing operations.
LH Block Electric surveyed the original facility to evaluate transformers, electrical distribution panels, disconnect switches, and other electrical components for reuse.
Suitable equipment was incorporated into the new installation, helping avoid unnecessary equipment replacement while accommodating the revised production layout.
The project required coordinating previously used equipment with the electrical distribution already present in the Palatine building.
This approach provided a practical solution that balanced the electrical requirements of the relocated manufacturing equipment with the resources already available.
Manufacturing Equipment Power & Distribution
The relocation required electrical distribution and equipment connections for manufacturing operations, including plastic injection molding equipment, pad printers, drying tunnels, and other production machinery.
LH Block Electric installed new conduit, copper conductors, equipment feeders, and dedicated electrical circuits throughout the manufacturing areas.
Existing transformers, panels, and disconnect switches were reused where suitable. Electrical distribution was modified to accommodate the machinery in its new locations.
The work also included electrical modifications throughout the office areas, including rerouting conduit and wiring affected by interior renovations and the removal of existing suspended ceilings.
These improvements allowed the electrical systems to be adapted to the building's new manufacturing and office layouts.
Coordinating the Manufacturing Relocation
LH Block coordinated equipment power drops ahead of the move from Rolling Meadows to the new Palatine facility. Preparing these connections before machinery was disconnected at the former location helped minimize downtime and keep production moving as equipment was relocated.
LED Lighting & Controls
As part of the renovation, LH Block Electric installed LED lighting and centralized lighting controls throughout the facility.
Four-foot LED strip fixtures provided consistent illumination across the manufacturing, office, and support areas.
The completed lighting work included:
- 175 four-foot LED strip fixtures throughout the facility, including stairwell and restroom lighting.
- 16 combination LED exit signs and emergency lighting units.
- 10 additional emergency battery-backup lighting units.
- An eight-zone lighting relay control system.
- Five wall-mounted lighting control stations.
- Integration of 13 additional soffit lights into the lighting control system.
The centralized relay-based lighting controls allowed designated areas to be operated independently, providing flexibility for the facility's manufacturing and office spaces.
The completed LED lighting improvements modernized the building's lighting while providing an efficient, practical solution suited to the new operations.
800-Amp Electrical Distribution & Rooftop HVAC Power
A major portion of the renovation involved adapting the building's electrical infrastructure to accommodate ten rooftop HVAC units.
LH Block Electric installed an 800-amp, 277/480-volt electrical distribution panel and integrated it into the building's existing electrical system to support the new rooftop HVAC equipment.
The installation included:
- Ten dedicated 480-volt, three-phase power circuits for rooftop HVAC equipment.
- Rooftop electrical disconnect switches and equipment connections.
- Conduit and wiring between the electrical distribution equipment and rooftop units.
- Raceways for thermostat and fire alarm duct detector wiring.
- Modifications to existing electrical distribution equipment.
- Refeeding two existing electrical panels through the installed distribution equipment.
The work required coordination with the existing service equipment, electrical room layout, and new rooftop mechanical installations.
Reusing suitable electrical equipment was consistent with the project's overall approach of making practical use of existing resources while meeting the facility's new electrical requirements.
Project Results
The completed electrical renovations helped transform an existing commercial building into a manufacturing facility capable of supporting three related businesses.
By combining manufacturing equipment power, strategic reuse of existing electrical components, LED lighting, and new HVAC electrical distribution, LH Block Electric provided a coordinated installation tailored to the building's new operations.
The project demonstrates our experience adapting existing commercial and industrial facilities, evaluating available electrical infrastructure, and developing practical electrical solutions for manufacturing relocations and facility renovations.
Electrical Solutions for Manufacturing Facilities
LH Block Electric provides commercial and industrial electrical services throughout Chicagoland, including Palatine and the northern and northwest suburbs. Our work includes manufacturing equipment power connections, electrical distribution improvements, LED lighting, and facility renovations.
Explore our CNC machine shop project in Bloomingdale for another example of electrical infrastructure supporting manufacturing operations.