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Fulton Completes Facility Expansion Construction

Fulton Companies, a global manufacturer of steam, hydronic and thermal-fluid heat-transfer products and provider of energy management solutions, announces the completion of construction on its major facility expansion project.

“The $10.5 million expansion features production efficiencies that are already allowing for increased response to customer demands,” said Mark Hilton, Fulton’s Vice President of Manufacturing. “The new facility will also provide the opportunity to expand Fulton’s product lines.”

The expansion’s manufacturing space is now fully functioning; office space transitions have begun and are expected to be complete in the first quarter of 2012. An additional $3.5 million will be spent to complete project interior and equipment needs.

The new space will provide 10,000 ft2 of new Research & Development space; 82,000 ft2 of new manufacturing space; 20,000 ft2 of additional office space; and 70 tons of additional lifting capacity at the Pulaski, NY, headquarters.

Guests will be encouraged to visit and see firsthand the cutting-edge building features for heating and cooling, lighting, and customized energy recovery.

Some of the facility’s innovative strategies are:
Heating: A heating system for the office space features a 12-zone in-floor radiant hydronic system. When there is a need for heat in this space, waste heat from either the factory’s Research & Development facilities, or its manufacturing processes, is assessed and used. This unique recovery feature will make a significant impact on the energy costs and efficiencies of the building.
Cooling: The office space is divided into 43 zones with a state-of-the-art chilled beam system mounted in the ceilings to efficiently distribute cooling to the building occupants. Cooling towers are incorporated to manage the energy balance of the overall system. For example, when waste heat exceeds the energy required by the system, excess energy can be rejected to the cooling towers. The system also has the potential to utilize gas-absorption heat pumps and retention ponds as an energy source.

Synex Controls energy-management system
The expansion has provided an opportunity for Fulton’s affiliate, Synex Controls, to integrate a custom state-of-the-art energy management system. The control system centralizes and manages the facility’s heating, cooling, fresh air, humidification and lighting. A Synex Web interface allows employees to interact with the heating and cooling system to capture comfort preferences. System-wide real-time data is readily available via the Internet, and there are plans to display the Synex control data for visitors in the facility’s lobby area.

An example of Synex’s leading-edge technology being used at the facility is the usage of real-time weather data, including current and predicted ambient conditions, to manage the heating and cooling loads. Sunrise/sunset times are also incorporated, to drive indoor and outdoor lighting needs.

The equipment installation and the Synex control system have been designed to integrate evolving technology over time, with the goal of keeping the overall system modern.

“Not only is this a beautiful facility that demonstrates some of the most advanced technology available in the industry, it also positions Fulton well for the future,” said Kathy Sega, Fulton’s Executive Vice President and General Manager for U.S. Operations.

In addition to the expansion site, Fulton maintains other facilities in Pulaski, NY; Ohio; Texas; the United Kingdom; and China.

For more information about Fulton, please visit For more information about Synex Controls, visit

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