Food Manufacturer
Emergency equipment breakdown with no contingency plan in place
Complete temporary cooling system, including Aqua Pro chillers, pumps, buffer tanks, heat exchangers and over 300 metres of flexible hosing
There’s never a good time for a critical equipment failure, especially if you’re running a 24/7 production facility. When one of the UK’s largest food brands experienced an emergency breakdown just a few days before Christmas, they needed nothing short of a miracle. Ben Davies, Aqua’s Hire Director, outlines how his rental team spread a little Christmas magic!
Situation
“With no contingency plan in place and a failed process cooling system, the client was really struggling” explains Ben. “Production had ground to a halt, and they’d already called a couple of suppliers to no avail. It was very much a case of third time lucky when they called our rental desk. They explained they needed to get their line back up and running – to at least 50% capacity – by the next day to avoid serious impact of downtime and financial ramifications.”
With the clock ticking, one of our technical project engineers liaised with the site maintenance team over the telephone to understand the application and identify the most effective rental solution.
Solution
The team set about preparing a 2MW cooling package for despatch to site ASAP. Early next morning a team of seven engineers were deployed to take delivery and install the rental equipment. This was a real team effort, with both Hire and Service engineers joining forces to try and beat the clock.
“In total, the team installed 2 x 760kW Aqua Pro chillers, pumps, buffer tanks, 4 x 500kW heat exchangers and over 300 metres of flexible hose. In just one day we managed to get the client’s production running at 100% capacity. This is testament to the technical ability and tenacity of all our engineers and their commitment to overcoming any challenges put their way” comments Ben.
Result
As well as getting production on track for the remainder of the Christmas period, our rental solution provided additional benefits to the customer. The Aqua Pro chillers within our hire fleet run on low GWP refrigerant and are highly energy efficient. In this example, when operating at 15°C leaving temperature, the units can extract an impressive 1000kW+ each. The units are designed specifically to withstand the challenges and demands of process applications.
Aqua continued to provide technical support to the client over the Christmas period, including helping them with the switch from generator to mains power. They can now focus on repairing, or replacing, their legacy plant, safe in the knowledge that their production is secure.
“For me, this is a great example of the importance of contingency planning” explains Ben. “Aqua offer free contingency planning – with absolutely no obligation or cost involved. Then, should the worst ever happen, you’ll have peace of mind that the kit you need will be immediately available for quick and straightforward install. It’s always easier to help a client when it’s a proactive, rather than reactive, response.”
For more information on our free contingency planning service call the team on 0333 004 4433.
Launched in the 2021 Budget, the Super Deduction is part of a two-year initiative designed to encourage investment and promote economic growth. Up until 31st March 2023, businesses investing in qualifying new equipment can still offset the cost against tax, plus an additional 30%.
With a focus on productivity and efficiency, the range of eligible equipment includes process cooling plant, such as chiller units. Under the scheme, corporation tax is effectively cut by up to 25 pence for every £1 invested and there is no limit or cap on the amount of capital investment that can qualify.
Here’s an example of how Super Deduction works in practice:
On top of these savings, upgrading to new equipment allows businesses to benefit from the latest, energy efficient, technology. For example, our Aqua Pro chiller range operates on R454B refrigerant as standard and offers fully integrated free cooling. Incorporating free cooling into your operation can reduce annual energy usage – and associated energy bills – by 80%+, when compared to a traditional refrigeration system.
So, not only can you save on tax, but you can also benefit from additional energy savings whilst reducing carbon impact and improving operational efficiency! The catch? There really isn’t one, although equipment does need to be purchased before 31st March 2023.
For more information on Super Deduction and qualifying equipment call the team on 0333 004 4433 or email sales@aquacooling.co.uk
Vertical Farming Company
Design a system to closely control the temperature and humidity levels of the vertical farming facility
A temperature control system which combines coils, chiller, and a tank with a variable speed pump set
Vertical farming offers a sustainable alternative to traditional methods of growing crops. It developed in response to challenges that conventional farmers were facing. It aims to produce higher quality, lower cost, pesticide free produce, reducing food waste and environmental impact. Here’s how Aqua helped with a temperature control system for a vertical farming application.
Situation
The vertical farming concept is effectively indoor farming, with everything carefully designed and monitored to ensure optimum growing conditions. Variables such as light, temperature, humidity, irrigation, and air composition are precisely controlled, and the process is pesticide free. The crops themselves are grown in vertical, stacked layers so footprint is kept to a minimum.
Aqua were tasked with designing a system to closely control the temperature and humidity levels of the vertical farming facility. Ideal growing conditions need to be simulated inside the farm so that resulting crops are both plentiful and high quality.
Solution
Our in-house design team created a system which combines coils, chiller, and a tank with a variable speed pump set. The chiller supplies chilled water to the coils. As the ambient air goes across these coils, the air temperature reduces and the humidity increases, to the required set point.
Results
Aqua have designed & supplied this solution, both in the UK and overseas. “It’s great to see how our cooling technology can be deployed in such a cutting-edge industry” explains Aqua Area Sales Manager, Mark Hopper.
“The potential vertical farming has to really make a difference with the agriculture and food sectors is quite astonishing. I’m proud that Aqua have been involved in such an innovative & sustainable project.”
Aqua have also developed a pump skid version of the system for the client’s US site. The skid is effectively plug & play format, just needing to be connected to the chiller, which the client purchased locally. Ironically, buying this element of the equipment from Aqua helped them reduce costs by 50% and cut lead time from 14 to 6 weeks when compared to purchasing locally. It also enabled the client to finish their project on time, so avoiding further financial implications.
For help with vertical farming projects, call the team on 0333 004 4433.
Free cooling is a method of using the ambient air to cool a process, rather than mechanical refrigeration. It dramatically reduces energy consumption, carbon impact and operating costs. Payback can be in as little as 6-18 months and annual energy savings can be over 80%.
There are two ways of adding free cooling to your process. You can choose a chiller that has free cooling built into it (integrated free cooling) or add a stand-alone free cooler to a standard chiller.
So, which option is best? That very much depends on the application and the site, but here’s a few things to consider that will help with the decision.
A system incorporating a chiller alongside a separate free cooler can be a great option if you have the advantage of space. As a guide, a free cooler needs to be around 50% bigger than the chiller so the equipment itself requires a bigger overall footprint. Conversely, a chiller with an in-built free cooling coil takes up much less space as everything is packaged within the one unit. For many clients, especially those where space is a challenge – and/or very costly – a free cooling chiller is often a sound choice.
Adding a free cooler to your system will involve installation work and resulting costs. You’ll need to allow for civil works, for example constructing a base for the cooler to sit on, which is normally constructed from concrete or fabricated metal. Electrical and mechanical works will be required and, if the cooler is going on the roof of a building, you’ll need to assess structural viability and potentially allow for additional support beams.
It’s much simpler to replace an existing chiller with a free cooling chiller. It’s a case of disconnecting the outgoing unit and connecting the new chiller. This type of installation is more akin to plug and play design and, therefore, less costly.
From a service & maintenance point of view, you have more components to look after with a chiller & stand- alone free cooler, so cost will be a little higher. That said, a free cooler does add redundancy to your system. In the unlikely event that the chiller develops a fault, the free cooler will enable production to continue, bridging the gap whilst an Engineer is arranged.
When it comes to performance, again things aren’t straightforward. If space allows, you can select any size free cooler to work alongside your chiller, so you could choose the biggest unit feasible. This will enable you to have a larger free cooling coil, which technically will allow free cooling to be achieved at higher temperatures than with an integrated free cooling chiller.
In addition, Aqua are the only UK based process cooling company to offer optimised free cooling. Our units can achieve free cooling within 3°C of ambient, compared to the industry standard of 10°C+.
If you’re interested in exploring free cooling further, talk to the team A free site survey and energy analysis will help you decide which is the best way to add free cooling to your existing process system.
Aqua Cooling are proud to be sponsoring the U10 Girls Panthers team at AFC Stoneham.
Aqua are supplying the team with their full match kit, training kit, tracksuit tops and rain jackets for the 22/23 season.
The team, managed by Richard Veal, are currently competing in the Hampshire Girls Youth Football League.
“This is the first season of competitive football for the girls. They only came together in July and have made tremendous progress both on and off the pitch. Our league journey started in September and the girls are currently unbeaten and hoping for promotion soon! We have a great team and are extremely grateful to have our Aqua sponsorship” explains Richard.
AFC Stoneham were formed back in 1919 and have 92 teams playing at various levels this season. The Club are committed to football for all ages, with a Player Development Centre, an FA Wildcats Centre and a Saturday Morning Fun Club. The number of Girls teams at Stoneham has risen dramatically, going from 2 to 24 in just 3 years.
“Aqua are proud to be sponsoring the Panthers“ explains Aqua Director, Simon Davis. “We’ve supported grass roots football for many years and are current sponsors of both Blantyre Victoria 2007 (Blues) who play in the Lanarkshire A Division and Ruskin Park Ravens U18 who compete in the Mid-Cheshire Youth League, so it’s great to be helping a girls’ team for a change! I had the pleasure of watching the Panthers play recently and they really are a side to be reckoned with. The talent is evident and we’re all excited to see how far they go this season.”
Aqua Cooling are now offering optimised free cooling within their EcoPro chiller range.
The Aqua EcoPro chillers achieve free cooling within 3°C of ambient, so at much higher ambient temperature than previously possible. This is due to the innovative arrangement of the units’ condenser coil. The EcoPro range has been specifically designed to maximise free cooling potential, so each model has an in-built free cooling coil with the largest surface area possible for its respective footprint.
“Whilst free cooling is widely recognised as a fantastic way of reducing energy costs and lowering carbon emissions, optimised free cooling takes things a step further” explains Aqua Sales & Marketing Director, Owen Hymers.
“Within our industry, similar products can achieve free cooling within 10°C of ambient temperature. However, with the Aqua EcoPro, free cooling is achievable within 3°C – a difference of 7°C+ over its competitors. Aqua are the only UK based partner to offer optimised free cooling currently and I think that’s evidence of our commitment to pushing boundaries when it comes to product innovation and finding the best solutions for our customers.”
“When you invest in an EcoPro chiller you benefit not only from a product designed to cope with the rigours of the process industry, but one that has impressive green credentials. Units operate on R454B, an environmentally friendly refrigerant with a GWP rating over 75% lower than R410A.”
With free cooling, ambient air is used to cool, rather than mechanical refrigeration. Energy consumption reduces, hand in hand with operating costs and carbon impact. Whilst it’s application specific, annual energy savings can be in-excess of 80%, giving payback in as little as 6-18 months and great return on investment.
Depending on unit size, the EcoPro chillers have either a 0.7mm thick copper coaxial evaporator or a shell & tube evaporator, constructed from 0.4mm thick copper. Both evaporator designs have large water pathways and the chillers come with a 3-year parts & 1-year labour warranty.
Ink Manufacturer
Unreliable Legacy Cooling System Causing Production Downtime
AquaPro Chillers and Free Cooling System
Aqua were approached by a global manufacturer of high-performance inkjet inks and pigment dispersions, who were looking for a review of their existing cooling system. Sales Engineer, Ben Newman, outlines how Aqua supported them with a centralised free cooling system.
Situation
Each of the clients’ paint process machines were individually cooled by an independent chiller unit. However, several of the chillers were nearing end of life so downtime was becoming a common theme within the production process. If a chiller failed, production in the associated print mill would come to a halt. An alternative system was required, one that would not only reduce downtime but also maximise reliability and efficiency.
The existing chillers were set at an 8°C supply temperature. Historical issues, including limescale build up and coolant fluid contamination, had resulted in site having to reduce the supply temperature to safeguard process performance. Introducing glycol had improved the situation, but the supply temperature had been kept at the 8°C set point.
Solution
Aqua quickly determined that the set point could be increased further, to 12°C.
This enabled us to suggest a new, centralised system, incorporating free cooling. In addition to improving process reliability and stability, it would also significantly reduce annual energy use and operation costs.
The new system consists of 2 x Aqua Pro chillers, with run & standby pumps, and a separate free cooler. The system is configured into run/run/standby, which simply means it collectively feeds all the print mills, rather than each mill having its own chiller.
Should a chiller fault ever occur, the remaining chiller & free cooler will pick up the load whilst maintenance is undertaken. Production downtime is zero and the system will continue supplying 12°C process fluid.
Utilising Aqua Pro units results in the pumps being integrated within each chiller – saving space and reducing costs. The chillers have additional connections already fitted so that capacity can be easily ramped up or down as and when required by adding a hire chiller.
Results
With a centralised run/run/standby cooling system, our client now has a highly dependable, extremely energy efficient alternative which will take their risk of downtime to practically zero.
Energy consumption and carbon impact will dramatically decrease, and their business is future proofed for years to come.
If production load is 70% of maximum capacity, the annual power consumption of the legacy system worked out to be £30,874 (based on 14 pence per kWh). Annual power consumption for the new free cooling system would be £17,072 – an annual electrical saving of £13,802/per annum. If production load is at 100% of max capacity, this saving increases to over twice this value per annum
A Global Plastic Component Manufacturer
Process Struggling During Summer Period
A Retrofit Adiabatic and Free Cooling Operation
As a global plastic component manufacturer, minimising downtime and operating costs is key. When our client found their process struggling to keep temperature during the warmer months, Aqua upgraded their existing equipment to include a retrofit adiabatic and free cooling operation.
Situation
A combination of chillers and dry air coolers were being used to cool the injection moulding tools and hydraulics. The moulding line, operating at 15°C, incorporated 4 water chillers, with a weir tank and set of duplex process pumps. The hydraulic line was separate and cooled by 2 dry air coolers.
In summer months, the dry air coolers were unable to maintain temperature. As a last resort, they created a makeshift adiabatic system by using a garden hose, however this would cause scale build up and damage the air blast coolers longer term.
Our client had already highlighted their dependency on mechanical refrigeration and had concerns over rising energy costs. They did consider a free cooling upgrade, but space on site had proved prohibitive. They were also hesitant on adding glycol into the mould cooling circuit because of the frequency with which the tools are changed.
Solution
After a site visit and full review of production requirements, Aqua proposed two changes to the existing system which would add resilience as well as significantly lowering running costs.
The issue over the warmer summer months was addressed by fitting an Aqua retrofit adiabatic system to the air blast cooler. Then, when ambient temperature is over 22°C, the unit can be used as an adiabatic cooler.
The retrofit involved installing a 10-bar spray system to the cooler. The spray is constructed from 304l thin-walled stainless steel. An adiabatic box with a speed driven spray pump regulates the water spray dependent on ambient temperature. An industrial UV filter treat the mains water used in the spray and the system fully drains and runs a flush cycle before use to ensure no risk of standing water and fully compliant with health & safety regulations. A salt free water softener on the mains water inlet protects coils from calcium deposit and risk of blockage over the longer term.
Our Engineers also determined that, outside of the summer months, the hydraulic circuit could be cooled by utilising just one of the existing air blast coolers. The second cooler would be separated and modified to become a free cooler, which would then sit on the refrigerated mould cooling circuit.
In addition, a heat exchanger fitted to the return line of the mould circuit would give the air blast cooler antifreeze protection over winter, whilst still allowing the mould circuit to run glycol free. A filter basket was added to improve filter quality, with a differential alarm alert if the filter becomes blocked.
Free cooling would be utilised when the ambient temperature is below 18°C, rather than mechanical cooling, dramatically reducing energy consumption, reducing carbon impact and operational costs.
Results
By adding adiabatic facility, the hydraulic circuit will now function correctly during the summer months. Utilising free cooling on the mould circuit is estimated to save the customer up to £70,000 per annum. From a payback perspective, total investment was £60,000. In addition, free cooling operation means the chillers will last longer as running hours reduce on the mechanical components for a significant period each year.
For more information on retro fit adiabatic and free cooling call the team on 0333 004 4433 or email sales@aquacooling.co.uk
Kent Based Plastic Manufacturer
Water Quality Compromising Production
Full Water Treatment Programme
Poor water quality was hindering production for a plastic manufacturer based in Kent. Aqua delivered a water treatment programme to resolve long-standing issues and to safeguard future production.
Situation
The client had experienced problems with their manufacturing process, which all stemmed from issues with their water quality. Despite trying several fixes, calcium build-up and water contamination continued to cause equipment downtime and wasted man hours. The tools were becoming clogged and blocked, leading to loss of cooling. As well as the impact of having to keep unblocking the tools, they often needed to be replaced which had unwanted cost implications.
Solution
Aqua proposed the installation of an automated side stream filtration unit and a schedule of water treatment works, to ensure that the correct water quality was not only achieved, but easily maintained on an ongoing basis.
Firstly, our Engineers carried out a full system flush over a five-day period, using a scale remover specifically designed to remove polymer build up. A specialist cleaning solution was then added to disperse any contamination into the fluid before filtering. Next, the entire system was re-flushed to eliminate any trace of the cleaning fluid.
After refilling, our Engineers added a biocide to destroy any bacteria present and carried out a third flush through. The final system fill included a multi metal inhibitor to negate any risk of oxidisation or corrosion.
With the legacy issues resolved, the automated filtration will ensure water quality is maintained by constantly cleaning it during the production process.
Results
As a result of the work, the client has a very clean water system which requires no manual intervention. It has restored reliability to their production schedule and will bring additional cost savings from them not having to unblock and replace their tools. The design of the filter also prevents water loss, something that is common if a standard back washing style filter is used.
For more information on how Aqua can support you and your business with water treatment call 0333 004 4433 or email service@aquacooling.co.uk
Temperature control specialists, Aqua Cooling, have been appointed as sole UK agent for German manufacturer Single. To mark the occasion – and to show how confident they are in their products – Aqua have launched a ‘try before you buy’ initiative.
Singles’ products include a range of energy efficient temperature control units (TCUs), including the EASiTEMP model. With standard operating temperatures of 95°C or 150°C, the EASiTEMP offers precise, powerful control to every application.
Temperature control units are utilised when a process requires heating – or heating and cooling – at high temperatures. TCUs are common in the plastic industry where they are used on extrusion and moulding lines, as well as in the food, pharmaceutical and automotive sectors.
With an analogue interface and unique Easi-Connect system, the EASiTEMP units are extremely quick to install. Cooling is via a brazed stainlesss steel plate heat exchange and solenoid valve, with all components well insulated to minimise energy usage. A check valve and strainer are incorporated on both the process and chilled water loop. A PID controller allows parameters to be easily adjusted and unit status is displayed by five LEDs on the front panel. The EASiTEMP units are also very easy to service and maintain as all the internal components are easily accessible.
The Single units are already winning acclaim amongst Aqua’s client base as Sales & Marketing Director, Owen Hymers, explains “Aqua are delighted to be Singles’ UK agent. The brand is synonymous with quality & reliability worldwide and fits well with our existing product offering. Feedback from our clients on the EASiTEMP has been extremely positive, not only do they love that the product has a small footprint and is easy to set up, but its ability to keep temperature and the automatic switch off feature are proving very popular.”
“Singles’ TCU units are market leading, and we are so confident that customers will love the product as much as we do, that we’re offering a free, no obligation, trial to customers. We have units in stock, at our Hampshire based warehouse facility, so delivery can be next day, UK wide.”
For more information and to arrange a free trial call the Aqua team on 0333 004 4433.
Low temperatures and harsh winter conditions put your chillers and HVAC equipment under added pressure – particularly if they’re sited outdoors.
When the ambient temperature drops, the water in your chilled water system can contract by up to 9% in volume. This potentially can cause a breakdown with a significant amount of damage to
components and pipework.
With so many facilities in the process of re-opening, some running with reduced staff levels and others between maintenance contracts, we’ve created some steps you can take to help keep your chillers and cooling equipment running efficiently.
By dosing your system with the correct level of glycol and maintaining this, you will prevent the water from freezing and causing damage to your system – minimising the risk of downtime and cost to your operation.
Most glycols these days also contain biocides and inhibitors that are essential for your systems continued health. Drops in this can cause bacterial blooms or electrolytic action which can strip aluminium and copper from your system.
With so many facilities in the process of re-opening, some running with reduced staff levels and others between maintenance contracts, we’ve created some steps you can take to help keep your chillers and cooling equipment running efficiently.
Rapid temperature drops can cause the water in your chilled water circuit to freeze quickly if it has not been dosed correctly with glycol. This can result in expansion which can lead to fractured pipework or at worst, burst pipes.
Your chiller pipework may be protected from freezing with trace heating tape.
If so, visually check the tape for any corrosion or damage, including any connections, to ensure it
continues to protect your pipework.
Due to the nature of this task, it would be advisable to get our Service Engineer to carry out more in depth checks and analysis, so that any fixes can be made safely, with the correct equipment to hand.
Your chiller’s strainer protects the pumps, heat exchangers and all other vital components from particles or contaminants.
Strainers can easily become blocked by scale, corrosion, biofilm, weld slag, dirt, iron oxides, and suspended solids. When the strainer is blocked, it can lead to pipe blockages, failed pumps and
then potentially make them susceptible to freezing issues.
Winter conditions can cause condenser coils and fans to work even harder.
By keeping them free from debris such as leaves and dirt, you will help to increase the efficiency of your chiller system – thereby reducing your operating costs. A blocked condenser will inhibit the rejection of heat, and a dirty coil can reduce airflow drastically. For each 10% reduction in airflow, the efficiency of the chiller drops by about 20%. If your chiller is fitted with a free cooling system, this will reduce the performance and therefore increase your energy costs.
Chilled water systems require regular maintenance checks and servicing to keep them running smoothly and efficiently.
Aqua provide Planned Preventative Maintenance programs, tailored to your business and operation. Our highly qualified, dedicated engineers get to know you, your business and facilities inside out – enabling them to provide a personal, consistent and exceptional standard of service.
To discuss how we can help improve the efficiency and maintenance of your chilled water systems,
please call on 0333 004 4433 or email service@aquacooling.co.uk.
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Bristol Aquarium is home to thousands of aquatic creatures, with over 40 displays and 250 different species. The animals come from across the world, and the aquarium is committed to conservation, sustainability, and education. Regional Sales Manager, Will Coles, outlines how Aqua have been supporting the facility with their temperature control.
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