AI+Zero-carbon: The World’s First Fully AI-Powered Chiller Lighthouse Factory

On March 28, Midea Building Technologies (MBT) hosted the launch event for the world’s first full-process AI-empowered chiller lighthouse factory in Chongqing. With its exceptional intelligent manufacturing capabilities and green industrial practices, MBT Chongqing chiller factory has earned the prestigious lighthouse factory designation.

Lighthouse Factories: Lighting the Path for Digital Transformation in Manufacturing

Lighthouse factories are recognized as the most advanced factories in the world, representing the highest level of intelligent and digitalized development in the global manufacturing sector. They drive the industry toward high-end, intelligent, and green manufacturing. As of now, there are 189 lighthouse factories worldwide, spanning 30 countries and 35 industries.

What sets MBT’s chiller factory apart is its application of AI technology across the entire process, from research and development to manufacturing and after-sales service. This factory, which began operations in 2004, specializes in manufacturing large-scale central air conditioning systems. Its products are widely used in airports, high-speed rail stations, industrial plants, commercial real estate, and data centers.

In recent years, the factory has faced challenges such as increasing demand for customized orders and greater complexity in quality control. In response, it has leveraged next-generation information technologies such as machine learning and augmented reality to explore new production models, including intelligent design, agile production, and customized delivery. These innovations have resulted in an 81% reduction in chiller selection cycles, a 45% decrease in product design cycles, and a 31% drop in maintenance rates.

Two Decades of Innovation: Leading the Evolution of China’s Chiller Industry

Since its establishment in 2004, MBT’s chiller factory has been committed to technological innovation, investing substantial financial and material resources. Progressing from technology adoption to independent innovation, it has consistently overcome technical barriers in the industry.

In 2006, MBT pioneered the launch of China’s first inverter centrifugal chiller. It subsequently introduced industry-leading high-efficiency falling-film centrifugal chiller, ultra-efficient two-stage centrifugal chiller, and high-efficiency inverter direct-drive falling-film centrifugal chiller. In 2019, MBT developed its own magnetic bearing centrifugal chiller, breaking technology monopolies. As a result, MBT’s centrifugal chiller sales have steadily increased, surpassing 1,000 units in 2021 and reaching 2,200 units in 2023, making it the top domestic brand in China.

Through continuous technological innovation, the factory has not only achieved full independent research and development of magnetic bearing centrifugal chiller but has also secured over 470 invention patents and won numerous international awards. MBT has consistently ranked among the top tier in the central air conditioning industry for 12 consecutive years.

“From being a follower to an industry leader, MBT has always embraced the spirit of pioneering innovation and continuous improvement. We push our own limits to make complex technology simple for our users, fulfilling our mission of delivering technology, professionalism, efficiency, and sustainability,” said David Li, R&D Head of Centrifugal Chiller of MBT.

At the event, MBT also unveiled the industry’s first 6600RT water-cooled chiller testing facility, with Jiang Li, President of China Refrigeration and Air Conditioning Industry Association, presenting the certification on-site. This testing facility evaluates the operation, performance, and reliability of water-cooled chillers, with a maximum testing capacity of 6600RT. It provides a solid foundation for innovative solutions in high-efficiency cooling and heating for large-scale equipment.

Full-Process AI Empowerment: Setting a New Benchmark for Intelligent Manufacturing

With the growing demand for customized orders, the factory’s digital transformation has not only enabled rapid response to customer needs but has also upgraded the entire R&D, manufacturing, quality, and after-sales chain.

For example, in the R&D phase, order selection used to rely on engineers manually sifting through millions of possible configurations, taking 30 engineers several days to determine optimal solutions that meet customers’ needs . Now, the factory utilizes a data platform with over 100 high-precision physics-based simulation models, achieving optimal selection with one-click automated quotations. This has reduced the selection cycle from 5.3 days to just 1 day. The factory also employs Midea’s self-developed PLM system, extracting design parameters from 230,000 historical blueprints and using AI algorithms for intelligent heat exchanger and pipeline design, cutting the design cycle by 45%.

The factory’s smart and flexible workshops for centrifugal compressors and heat exchangers have significantly optimized production layouts, equipment configurations, production processes, and logistics. This has led to a 30% increase in efficiency, a 15% reduction in costs, and a QR code tracking system ensuring comprehensive quality control.

In terms of maintenance, AI-powered diagnostics proactively predict faults and performance degradation, offering smart operation and maintenance recommendations via the mobile app and the computer system. These measures have reduced market service complaints by 37% and in-warranty maintenance costs by 21%.

MBT Chongqing chiller factory is also a model of sustainable development, implementing zero-carbon initiatives through process optimization, smart energy management, and carbon offsetting. The factory has earned multiple prestigious green certifications, further solidifying its leadership in green manufacturing.

Currently, the factory’s large-scale central air conditioners are widely used in landmark projects worldwide, from Beijing Daxing International Airport and Shanghai Citi Tower to global locations such as Cyprus’ Mary 260MW power plant and Thailand’s Big C retail complex. As China’s manufacturing sector undergoes transformation, MBT’s success provides valuable insights, heralding a new era of intelligent and green manufacturing.