By Allie Brawley
Cloverland Electric Cooperative’s hydroelectric plant, a historic marvel in Sault Ste. Marie, Michigan, is set to receive a major upgrade: four new runners for its turbines. This crucial step reflects the cooperative’s commitment to maintaining its 123-year-old facility, which generates 30% of its fuel mix and keeps rates low for its members. The runners, integral to the plant's operation, are being crafted by Hacker Industrial, a third-generation family business in Brazil with a rich history and cutting-edge expertise.
A Legacy of Hydropower and Innovation
The Hacker family’s story is woven into the fabric of hydropower innovation. The company was founded by a German immigrant who settled in Brazil, bringing with him a passion for engineering and an entrepreneurial spirit. He began by tinkering with turbine parts in a modest shop, laying the groundwork for what would become one of the few manufacturers worldwide capable of creating parts for niche hydro plants like Cloverland’s. Over three generations, the Hacker family honed their craft, working side-by-side on the shop floor and expanding the business to include a wide range of hydraulic turbines, accessories and electric generators.
Today, Hacker Industrial is a leader in producing components for smaller hydro plants. This specialization, coupled with a reputation for quality and innovation, made them an ideal partner for Cloverland’s needs. Hacker’s client focus has been in Brazil and they have recently expanded to North America.
As part of the quality control process to inspect the build and design measurements before accepting the product, Cloverland’s Hydro Plant Manager, Michael Panik traveled to Hacker’s facilities. Just like Cloverland’s mechanics will inspect all new fleet vehicles to verify and validate the quality of the product, this protocol is standard for major co-op purchases.
The facility visit also involved seeing Hacker’s capabilities for future hydro parts. Hacker provides expertise and value to Cloverland since there are very few hydro turbine manufacturers willing to create parts for smaller plants. Learning the nuances and best practices that can be applied to Cloverland’s hydro plant is vital to the co-op’s infrastructure and rates that rank among the lowest in the state.
The Journey to Partnership
Cloverland’s search for a vendor began with a publicly posted request for proposals (RFP). Hacker’s team stood out not only for their competitive pricing but also for their unmatched qualifications. Once selected, Hacker engineers visited the hydro plant in March 2024 to conduct detailed 3D scans of the existing turbine parts. Using these scans, they reverse-engineered the runners, ensuring precise dimensions and bolt patterns that would seamlessly integrate with the plant’s vintage 1916 turbines of the plant built in 1902.
The manufacturing process involved static balancing tests and rigorous quality control at Hacker’s pristine facilities, where every step met or exceeded standards.
“From their facilities, process control, and attentive customer care, it was evident that we had selected an outstanding vendor,” said Michael Panik, Cloverland’s Hydro Plant Manager, who brings two decades of engineering experience with the U.S. Army Corps of Engineers.
Preserving History While Embracing the Future
The Hacker team’s work is more than an engineering feat; it’s a bridge between history and modernity.
“Hydro parts are always in need of being refurbished and eventually replaced, so it is important to create relationships with vendors who truly understand our long-term needs,” said Roger Line, Cloverland’s Director of Generation who started as a repairman and understands all the nuances of keeping a 123-year old plant running efficiently.
Hacker facilities are immaculate and quality control is highly scrutinized to meet standards because they value their reputation. By choosing Hacker, Cloverland ensured significant cost savings while securing a vendor relationship that promises to support the plant for years to come. As a member of the National Hydropower Association and the Midwest Hydro Users Group, Cloverland continues to advocate for hydropower’s vital role in the renewable energy landscape.
Looking Ahead
The new runners are set to be installed in early 2025, marking a milestone in Cloverland’s ongoing effort to maintain and modernize its infrastructure. The partnership with Hacker exemplifies the cooperative’s commitment to preserving its historic legacy while powering the community with clean, reliable energy for generations to come.