How Procon Powered Linamar’s New Giga Factory: Inside a Landmark EV Manufacturing Project

The global shift toward electric vehicles has created unprecedented demand for advanced manufacturing facilities capable of producing lighter, stronger, and more efficient vehicle components. At the center of this transformation is gigacasting—a revolutionary process that uses massive high‑pressure die‑casting machines to create large structural EV components in a single shot.

When Linamar, one of North America’s most respected automotive suppliers, set out to build a 300,000‑square‑foot Giga Factory, they needed an electrical contractor with the expertise, scale, and precision to power a facility of this magnitude. They chose Procon Constructors Inc., a leader in multi‑trade industrial contracting known for delivering complex electrical, mechanical, SCADA, and instrumentation projects across the ICI sector .

The result is a state‑of‑the‑art manufacturing hub that strengthens the North American EV supply chain—and showcases Procon’s ability to engineer and install the high‑voltage systems required for next‑generation production.

What Makes the Linamar Giga Factory So Significant?

Linamar’s new facility represents a major leap forward in EV manufacturing. It houses three 6,100‑ton gigacasting machines, among the largest in the world, capable of producing massive aluminum components that traditionally required dozens of welded parts.

This shift offers major advantages:

• Reduced production time

• Lower manufacturing costs

• Improved structural integrity

• Lighter EV components for better efficiency

But gigacasting machines demand enormous, stable electrical power—far beyond what a typical industrial facility requires. That’s where Procon’s expertise became essential.

High‑Voltage Power Distribution: The Heart of the Facility

To support the gigacasting equipment, Procon installed a 27.6 kV high‑voltage service with redundant feeds, ensuring uninterrupted operation even under extreme load conditions. The incoming power was upgraded using two 5 MVA transformers, each capable of delivering the massive electrical capacity required for continuous casting operations .

From there, Procon engineered and installed:

• A 5000A switchboard

• Multiple 2000A distribution boards

• Strategic power routing to each gigacasting machine

This infrastructure forms the electrical backbone of the entire plant, enabling high‑pressure die‑casting cycles to run safely, efficiently, and consistently.

Lighting, Life Safety, and Facility‑Wide Electrical Systems

A facility of this scale requires more than raw power—it needs intelligent, efficient, and safe electrical systems throughout.

Procon delivered:

• Energy‑efficient LED lighting across the full 300,000‑square‑foot plant

• Emergency power systems

• Fire alarm and life‑safety infrastructure

• Egress lighting for safe evacuation

• Integrated safety controls tied into automation systems

These systems ensure the plant operates safely while minimizing energy consumption and maintenance costs.

Advanced Power Monitoring and Automation Integration

Modern EV manufacturing relies heavily on real‑time data. To support Linamar’s operational goals, Procon deployed advanced metering systems and tied them into the facility’s building automation network.

This allows Linamar to monitor:

• Energy usage

• Load distribution

• Power quality

• System performance

• Predictive maintenance indicators

By integrating electrical systems with automation controls, Procon helped create a smarter, more efficient manufacturing environment—one capable of adapting to production demands and optimizing energy consumption.

Why Procon Was the Ideal Electrical Contractor for This Project

Large‑scale EV manufacturing facilities require a contractor with deep technical expertise, proven industrial experience, and the ability to coordinate multiple trades seamlessly. Procon brought all of that—and more—to the Linamar Giga Factory project.

1. Multi‑Trade Capabilities

   Procon provides electrical, mechanical, SCADA, and instrumentation services under one roof, reducing project complexity and ensuring consistent quality.

2. Proven Experience in High‑Voltage Industrial Projects

   The company has a long track record of delivering complex power systems for manufacturing, processing, and heavy industrial facilities.

3. Precision, Safety, and Reliability

   Every component—from transformers to life‑safety systems—was installed with meticulous attention to detail and strict adherence to safety standards.

4. Ability to Scale for Massive Projects

   A 300,000‑square‑foot facility with gigacasting equipment is a rare undertaking. Procon’s team scaled seamlessly to meet the demands of the project

A Milestone for North American EV Manufacturing

The Linamar Giga Factory is more than a new facility—it’s a strategic investment in the future of electric mobility. It strengthens the EV supply chain, creates new jobs, and positions Linamar as a leader in high‑pressure die‑casting innovation.

Procon’s work ensures the facility is powered, protected, and prepared for the next generation of EV production. Their contribution demonstrates not only technical excellence but also a commitment to supporting the growth of sustainable manufacturing across North America.

Final Thoughts: Powering the Future with Procon

As the automotive industry accelerates toward electrification, the demand for advanced manufacturing facilities will continue to grow. Projects like the Linamar Giga Factory require electrical contractors who understand high‑voltage systems, industrial automation, and the unique challenges of EV production.

Procon has proven they are more than capable—they are leaders in powering the future of manufacturing.