The Client –
Proplastix, specialist injection moulder
The Challenge –
Chiller failure
The Solution –
Temporary hire chiller & supply of a free cooling chiller
Proplastix, based on the Hampshire/Dorset border, have more than 35 years’ experience of moulding components and are true specialists within their field. They have a range of moulding machines on site, from 25 to 150 ton, with the capability to mould in the full range of thermoplastics. This includes, the high temperature, exotic and metal replacement materials such as Polysulphone, PEEK, Liquid Crystal Polymer, PPS, PES, Ultem, IXEF.
Aqua were approached by Proplastix, when their existing chiller failed, putting their production schedule at risk. Their local Sales Engineer, Joe Malone, went to site to ascertain the full extent of the problem and to determine the best way forward for their business.
Situation
Reliable process cooling is crucial within the plastic injection moulding sector because it regulates the optimum temperature of the mould. This ensures efficiency, quality, and consistency throughout the manufacturing process. If the mould temperature isn’t consistent, the end product can have defects such as warping, sink marks and internal stresses, leading to costly wastage.
In addition, precise cooling ensures the product solidifies correctly, helping to increase production rates and overall efficiency. By keeping the mould at a safe temperature it avoids repairs being needed and extends its lifespan.
The existing chiller was an 85kW unit, which provided cooling to 9 injection moulding machines. With the chiller – and their production – down, Proplastix needed to rectify the situation as quickly as possible to avoid further downtime, production delays and subsequent costs.
Solution
With production at a standstill, Joe immediately secured a rental chiller from our hire fleet, to get the production line back up and running as quickly as possible.
After a quick run through of Proplastix’s process and working temperatures, a quick load calculation established that their legacy unit had been oversized by 10kW, meaning they could replace it with a smaller, lower cost, 75kW chiller.
But, even more significant, they required a supply temperature to their process of 18°C. This allowed them the option of considering utilising free cooling technology which would dramatically decrease their energy consumption, operation costs and carbon footprint.
When you add free cooling to your process, it enables the natural ambient air temperature to be used for cooling, rather than energy intensive mechanical cooling. For Proplastix, this meant that anytime the ambient temperature is 11°C or less, they’ll take advantage of 100% free cooling. Above that temperature, but less than 17°C, they’ll benefit from partial free cooling, where the refrigeration circuit and free cooling circuit share the load.
As a result, we supplied a 75kW chiller from our Aqua EcoPro range. These units have an in-built free cooling coil, so everything is completely integrated. They’ve also been specifically designed for process applications, so as well as being highly efficient they’re robust and very dependable. They operate on low GWP refrigerant, include EC fans, electronic expansion values and a unique, cleanable process evaporator.
Results
“At Aqua we pride ourselves on thinking outside the box and ascertaining the best options for the client longer term” explains Aqua Engineer Joe.
“On the face of things, it would have been easy to just replace with a like for like unit, but by understanding Proplastix’s process and specific requirements it allowed us to provide a solution that will benefit them for the longer term.
“The chiller unit will achieve full payback within a couple of months and Proplastix should save in excess of £38,000 per annum. That’s over £381K over a ten year period!”
When asked for his thoughts on the project, Tom Boreham, Production Manager at Proplastix was very complimentary. “The team at Aqua Cooling are exceptional to work with, from the initial consultation to the installation and ongoing support. They’re knowledgeable, responsive, and always willing to go the extra mile. We couldn’t be happier with their service.
“Since installing the free cooling chiller, we’ve seen a significant improvement in our cooling performance and energy efficiency. Our temperatures are more consistent, and our energy bills have gone down. We’re very happy with the results. The chiller is incredibly easy to use, and the controls are very intuitive.”
If you’re working within the plastics sector, give the team a call and see how Aqua could help improve your process cooling system. 0333 004 4433.
