Built for the future

Winnipeg’s West End Radiators puts safety at the core of new manufacturing facility

By Jeff Baker

When a company has been a fixture in Western Canada’s manufacturing community for more than half a century, every major capital project carries extra weight.

For Winnipeg-based West End Radiators—a long-respected manufacturer and service provider of heavy-duty heat exchangers—the opening of its new copper-brass manufacturing facility marks not just an operational milestone, but a meaningful shift in how the company approaches safety, growth, and the next generation of production.

And according to Justin Feeleus, Owner and Director of Plant Operations, this expansion was long overdue.

“After opening our copper-brass manufacturing plant over 20 years ago, we were outgrowing the original space,” Feeleus explains. “It had grown much bigger than the space we had for it.”

So, why did West End Radiators choose now to expand, how did they design a safer and more efficient facility from the ground up, and what might other Prairie manufacturers take from their journey.

Growing beyond the limitations of the old facility

For decades, the company’s copper-brass core manufacturing operations were tucked inside the service centre of its Winnipeg shop—a layout that worked in the early 2000s but became increasingly strained as production volumes grew and customer demands evolved.

“The biggest issue was lack of space since our manufacturing centre existed in the same space where we service heat exchangers,” Feeleus says. “This meant we had multiple departments coming and going in one area.”

Anyone who has worked in a mixed-use industrial space knows the ripple effects: workflow congestion, shared hazards, reduced efficiency, and limits on what jobs can safely be completed at the same time.

West End Radiators had seen the advantages of a dedicated environment through its standalone aluminum core manufacturing plant.

“We saw how successful having a stand-alone aluminum core manufacturing plant was,” says Feeleus. “We knew having copper-brass core manufacturing in a separate building would have the same benefits—allowing us to expand and grow the way we want to.”

The decision became clear. To support future growth—and provide workers with the safest, most modern environment possible—the company needed a purpose-built copper-brass facility.

Designing for safety first

Across the Prairies, manufacturers are navigating a shifting landscape of labour availability, workplace expectations, technological change, and rising regulatory standards. Safety is no longer just a compliance checkbox—it’s a competitive advantage and a foundation for attracting and retaining skilled workers. West End Radiators built its new facility with that philosophy top of mind.

“A huge priority in the new plant was ventilation for us,” Feeleus emphasized. “The old space was set up 20 years ago, and since then a lot has changed with codes.”

The new system is engineered to meet modern regulatory requirements, improve air quality, and reduce exposure to heating and soldering fumes typically associated with copper-brass manufacturing.

“This new space has top-of-the-line ventilation, fresh air coming in, and is up to code,” notes Feeleus. “It gives us and our team peace of mind that they’re working in a safe space each day.”

The company is already planning further enhancements. “We have big plans to eventually go 100% lead-free, which will improve our health and safety even further.”

Segregated operations = fewer hazards

Perhaps the most overlooked safety improvement—yet one that workers feel immediately—is the separation of manufacturing from service operations.

“It’s so much safer now that manufacturing and service don’t share a space,” Feeleus explains. “For example, we don’t have a forklift driving through the area to move a part to shipping. We can just focus on building new cores for our customers.”

The result is a cleaner, quieter, more controlled work environment—conditions that directly reduce risk while also improving morale and focus.

Investing in modern machinery and automation

Many manufacturers face the same question when planning capital upgrades: how far to push automation, and how quickly? West End Radiators is taking a measured, strategic approach—focusing on areas where automation improves both quality and safety.

“We’ve invested in some new machinery that is industry-leading,” Feeleus shares. “And we’ve recently introduced automation to our header dipping process.”

The header dipping stage—traditionally a manual or crane-assisted process—has long presented ergonomic and safety challenges in copper-brass core production. Automating this step reduces physical strain on workers, lowers risk, and increases consistency in the final product.

This philosophy—targeted automation that enhances safety while preserving craftsmanship—is increasingly common among small and mid-sized manufacturers across the Prairies.

A layout that supports complex, large-scale jobs

In heavy-duty heat exchanger manufacturing, no two projects are identical. Jobs vary by equipment type, size, application, and customer requirements. That means space—and how that space is organized—matters. The new facility dramatically improves flexibility.

“With more space, we are able to complete jobs of any size,” says Feeleus. “And this is only Phase 1.”

“We plan to add an addition in the coming years to expand the plant further—making room for cranes and other lifting mechanisms that will allow us to build even bigger cores.”

This phased approach mirrors the growth strategies of many Prairie manufacturers: build for today, but design with tomorrow clearly in mind.

Improved workflow and cleanliness

Manufacturers know that productivity isn’t just about machines or floor space—it’s about flow. The previous layout forced workers from multiple departments to intersect, often competing for the same space or equipment.

The new plant eliminates those bottlenecks entirely, allowing manufacturing tasks to progress in a logical, uninterrupted sequence. This has also improved housekeeping.

“We wanted to improve shop flow, organization, and cleanliness,” Feeleus says. “And having this dedicated space allows us to do exactly that.”

Efficiency and safety often go hand-in-hand, and the new building has already demonstrated this principle in practice.

Faster turnarounds, greater capacity

Manufacturing upgrades are only worthwhile if they translate into improved value for customers—and West End Radiators is already seeing meaningful changes. The biggest shift? Speed.

“We envision our copper-brass manufacturing department evolving to eventually have multiple shifts,” Feeleus says. “That will improve our lead times for customers even further.”

With the ability to add shifts, take on more complex jobs, and scale production quickly, the company sees opportunities to elevate customer service far beyond what the previous facility allowed.

“We can build their heat exchangers overnight, which we couldn’t before.”

For customers in industries like transportation, agriculture, mining, and construction—where equipment downtime is costly—that speed can make a significant difference.

Strategic growth for the next decade

West End Radiators’ new facility is more than an upgrade—it’s a strategic investment in the next five to 10 years of Prairie manufacturing. But underlying it all is a people-first approach.

Every square foot of the new facility reflects a commitment to the team—safer ventilation, fewer shared hazards, clearer processes, and more room to do high-quality work with pride.

That philosophy is increasingly defining the future of manufacturing across the region and country. Companies that invest in their people—through better environments, modern tools, and safer processes—are the ones best positioned to attract talent and thrive in the next decade.

Looking ahead

For West End Radiators, the new facility represents both an achievement and a beginning. It provides room to grow, tools to innovate, and, above all, a safer, more effective environment for the skilled people who make the company what it is.

The manufacturing landscape is changing—and West End Radiators are showing what it takes to lead that change with confidence, clarity, and care for the people who make it possible.