In a bold move to disrupt the American lubricant industry, WOW Lubricants (Wurtland Oil) is turning an abandoned Kentucky site into a cutting-edge production hub, while betting on press technology to get the job done. Establishing its first U.S. manufacturing facility is a strategic move, designed to challenge major industry players and carve out a significant market share. This project involves the complete redevelopment of a former industrial site in Wurtland, Kentucky, into a state-of-the-art blending and packaging plant for a wide range of industrial, automotive and transport lubricants.

At the helm of this complex operation is David Makin, Chief Operating Officer of WOW Lubricants. With an extensive background in plant management, mechanical integrity and more than a decade of firsthand experience with Viega systems, David combines deep technical knowledge with strategic leadership to drive operational excellence, ensure safety and foster continuous innovation. Makin was faced with a dual challenge of building a new state-of-the-art facility with a compressed timeline. He convinced his team that modern press technology was a superior choice over traditional piping methods.

“I’ve been using Viega products heavily over the last six years, and my trust in the systems goes back 12 years,” said Makin. “Having managed large-scale facilities across the US, I understand the disadvantages of welding—the extensive time, the high costs, the constant need for quality assurance and the inherent safety risks. Viega's systems offer faster installation and maintenance, making it a no-brainer for this project.”

The Challenge: From Industrial Relic to High-Efficiency Plant

The chosen site for WOW’s new beginning was a sprawling property on Harris Road in Wurtland, Kentucky, previously operating as a manufacturing plant. After closing in 2022, it fell into disrepair, presenting WOW with significant hurdles. The team inherited a site with frozen equipment, widespread water damage and aging infrastructure that was unsuitable for the precise and demanding process of lubricant production.

“We’re partnering with contractors on the civil and infrastructure phases of the project, while our highly trained in-house maintenance team works seamlessly alongside them. This close collaboration will streamline the process, control costs and keep the project on pace with our aggressive schedule,” Makin explained.

The facility’s layout has been strategically designed for optimal workflow, featuring a 50,000-square-foot production building connected to an enormous 800,000-square-foot warehouse.

The completed production facility will be used for blending and producing various products, while the warehouse will store the finished products. The layout is designed to optimize the production process. The types of oil blends and products that will be produced at the facility are:

• Motor Oils: 10W-30, 10W-40 and 15W-20, which are essential for various engine types.
• Grease and Lubricants: Crucial for maintaining machinery and reducing friction in mechanical systems.
• Diesel Exhaust Fluid (DEF): Used in diesel engines to reduce emissions.
• Antifreeze: A key in preventing engine coolant from freezing in cold temperatures.

Industrial Lubricant Production Requires Complex Piping Systems

WOW’s production of industrial lubricants requires complex piping systems that must handle various fluids, temperatures and pressures while maintaining absolute system integrity. Traditional joining methods like welding, threading and soldering pose several critical risks:

• Risk of Contamination: Slag, flux or other debris from welding or soldering could enter the pipelines, compromising the quality of sensitive oil blends.
• Extended Downtime and Installation Time: Permit requirements, fire watches and extensive setup can lead to construction delays and increased labor costs.
• Safety Hazards: The presence of open flames and hot equipment in an environment that will eventually handle flammable materials presents a significant safety concern.
• Inconsistent Quality: Achieving sealed, reliable joints with welding across thousands of connections in a massive facility is difficult and heavily dependent on installer skill.

The Solution: A Strategic Partnership with Viega 

After evaluating multiple options, WOW selected Viega's press technology as its preferred piping solution. Viega’s system is built for exactly this kind of high-demand fluid handling.

“Viega’s innovation and efficiency speak for themselves,” Makin said. “They proved their value during a previous plant expansion, so bringing them on for this project was an easy decision.”

As a global market leader in press technology, Viega provides systems that directly address the challenges of industrial fluid handling. The decision was driven by Viega's proven performance and a suite of features perfectly suited for the demands of lubricant production.

Key Features:

• Flameless Connections: Viega ProPress® and MegaPress® systems create secure, permanent connections in seconds without an open flame, eliminating fire risk and the need for flux permits.
• Unmatched System Integrity: Press fittings provide clean, consistent and reliable seals that protect against contamination and leaks.
• Smart Connect® Technology: This patented Viega feature is a crucial quality assurance tool, helping installers easily identify any unpressed connections during pressure testing, guaranteeing the integrity of the entire system.
• Versatility and Range: With fittings available in multiple materials and a comprehensive range of diameters, Viega provides a single, reliable solution for diverse piping needs, from utility lines to process-critical transfer lines

Implementation Process: A Phased and Collaborative Approach

Viega engineers are collaborating with WOW's facility planners to design and optimize system configurations for everything from nitrogen and water lines to air and product transfer lines. This includes:

• Installer Training: While contractors will handle the initial large-scale pigging system, WOW’s in-house maintenance team will be responsible for a large portion of the installation and ongoing maintenance. Viega will provide on-site training to ensure every press is made to specification.
• Phased Implementation: Installation begins next month in strategic phases, starting with water lines, sewer lines, ADA-compliant bathroom renovations and progressing to the complex process piping.
• Quality Verification: Before the system goes live, every connection will be tested, with the Smart Connect feature providing a clear and simple method for verifying the integrity of the entire network.

Positioned for Expansion, Powered by Press

The successful implementation of Viega press technology at WOW demonstrates how modern connection systems can address the complex challenges of industrial fluid handling. By selecting Viega's solution, WOW has positioned its new facility for optimal performance, enhanced safety and simplified maintenance for years to come.

WOW expects to expand its operations with a warehouse on both the West and East coasts. With the ability to ship by rail, barge and box truck, the Ohio River will play a crucial role in shipping and receiving materials. As a valued partner of Viega, they’re poised to keep growing.