The Client –
Plastic injection moulding business, based in North East England
The Challenge –
Failed equipment leaving process operating on mains to drain cooling
The Solution –
Upgraded adiabatic cooling system plus customised pump & tank skid
Equipment failure had led a plastic injection moulding business to revert to using mains to drain water to cool their process. They operate a range of moulding presses, right up to 1,000 tonnes, which run 24 hours a day. As a supplier to key sectors, including aerospace, automotive and defence, and with summer just around the corner, they urgently needed a long-term solution to keep their business operating effectively and efficiently going forward.
Situation
Process cooling plays a vital role within the plastics industry. For injection moulding, it helps maintains the quality of the product. As plastic cools it shrinks, so carefully controlled cooling prevents shrinkage and warping. It also helps to keep the moulding equipment and hydraulic oil cool, stopping overheating which can cause damage and reduce its lifespan.
Our customer had been using a closed cooling system, but their existing adiabatic unit had frozen during the winter and was left beyond economical repair. This left them dependent on mains water to cool their process, which was then discharged into the drain. They were extremely aware of the inefficiencies and disadvantages of this method, and with summer rapidly approaching, asked Aqua to provide a replacement system.
Issues experienced using mains to drain, can include:
- Excessive water usage – water is a precious commodity but mains to drain wastes water which is bad for the planet, as well as business.
- High costs – water wastage has financial implications plus high temperature water can incur additional utility charges because of the additional processing and filtration needed by the sewage system.
- Contamination risk – the water can pick up contaminants from the process, which then pollutes the water which negatively impacts the environment.
Solution
A site visit quickly confirmed that, with a 250kW load and a requirement for a 25ºC water supply all year round, adiabatic cooling was the best option. Plus, with the required capacity adiabatic cooler in stock in our warehouse in Southampton, we could offer the client a quick resolution and get them off mains water before the warm weather hit. This would safeguard their production, as well as allowing them to benefit from the associated energy & cost savings.
Adiabatic coolers lower air temperature by taking advantage of water evaporation and the resulting latent heat absorption. They operate in the UK in “dry mode” for most of the year. But, on the hotter summer days, the adiabatic mode activates and sprays a high-pressure water mist across the air stream. The evaporation of that water provides an “adiabatic effect,” lowering the air temperature without the need for refrigerants or additional mechanical cooling.
Adiabatic cooling is a great option if your required working water temperature is 25ºC+. In addition, Aqua offer an optimised version, which achieves a careful balance between load, water usage and fan speed. An innovative control management system ensures the water spray is only used when necessary. This results in maximum water evaporation with minimum water wastage.
As well as being energy and cost efficient, with a solid return on investment, adiabatic coolers require minimal maintenance. The spray nozzles on Aqua unit are designed for industrial applications and easy to clean by simply unscrewing, brushing, and replacing. They come with EC fans as standard. Spray pipework is stainless steel, rather than plastic, and the coil has a hydrophilic coating, all to minimise any risk of corrosion.
Along with the adiabatic cooler, we supplied a combined pump and tank skid. This was designed and built at our manufacturing facility at our Northern HQ. This gave the client a completely customised solution and, being UK manufactured, meant we could turn things around quickly to aid the project timeline.
Installation was conducted over a two-day shutdown, keeping business disruption to a minimum. The new equipment was bought onto site on a HIAB, which also removed the redundant cooler. Our installation team reconfigured the existing pipework and added new stainless-steel pipework. The client is also covered by one of our Planned Preventative Maintenance Plans (PPM) which will keep their system working correctly for the future.
Results
“Sometimes, you can make a significant difference to a client’s business without having to make any big changes” explains Aqua Regional Sales Manager, Mark Whittaker.
“The client was familiar with the benefits of adiabatic cooling from experience, so quickly understand the added advantages of Aqua’s optimised version. Speed of response was really the most crucial aspect of this project, it was about getting the client onto a dependable, closed system before the hotter summer temperatures arrived.
“By having the required unit in stock, and our own manufacturing facility to step in and produce the pump & tank skid, we could turn things around quickly. Our client is now reaping the benefits of a dependable, sustainable cooling solution which will reduce their operating costs, safeguard product quality and vastly improve their green credentials.”
If you’re working within the plastics sector and/or are looking for a support with an adiabatic cooling system, chat with the team today on 0333 004 4433.
