0333 004 4433
  • Sales

    CHILLERS

    Process Chillers

    OEM Chillers

    Free Cooling Chillers

    Low GWP Chillers

    AMBIENT COOLING

    Cooling Towers

    Dry Air Coolers

    Free Coolers

    Adiabatic Coolers

    TEMPERATURE CONTROL UNITS

    Temperature Control Units

    DESIGN & INSTALLATION

    Our Design & Installation Services

    DATA CENTRE COOLING SOLUTIONS

    CDU with Leak Prevention

    CRAC / CRAH Units

    ANCILLARIES

    Water Treatment

    Industrial Chilelrs
  • Hire

    CHILLERS

    Heat Pump Chiller Hire

    HVAC Chiller Hire

    Industrial Heat Exchanger Hire

    Low Temperature Chiller Hire

    Non Ferrous Chiller Hire

    Process Chiller Hire

    Water Cooled Chiller Hire

    Water Storage Tank Hire

    AIR CON

    Air Conditioner Hire

    Air Handling Unit Hire

    BOILERS

    Boiler Hire

    Electric Boiler Hire

    Fuel Tank Hire

    HEATERS

    Electric Heater Hire

    Heater Hire

    Industrial Heater Hire

    Office Heater Hire

    COLD STORES

    Chilled Storage Hire

    Low Temperature Fan Coil Hire

    FREE COOLING

    Adiabatic Cooler Hire

    ANCILLARIES HIRE

    Water Treatment
    Industrial Chillers Hire
  • Service
    • Emergency Breakdown
    • Glycol
    • Service & Maintenance
      • Air Conditioning
      • Chiller Maintenance
    • Spare Parts
    • Water Treatment
  • Industries
    • Agriculture & Farming
    • Automotive & Manufacturing
    • Brewery & Distillery
    • Petrochemical, Oil & Gas
    • Data Centre Cooling
    • Defence, Military & Government
    • Education & Research
    • Facilities Management
    • Food & Beverage Manufacturing
    • Metal Finishing & Tooling
    • Pharmaceutical & Medical
    • Plastics, Rubber & Packaging
  • News & Success Stories
    • Success Stories
    • Latest News
  • About
    • Careers
    • FAQs
  • Contact
  • Sales
    • Chillers
    • Ambient Cooling
    • Temperature Control Units
    • Design & Installation
    • Data Centre Cooling
    • Ancillaries
  • Hire
    • Chiller Hire
    • Air Con Hire
    • Boiler Hire
    • Heater Hire
    • Cold Store Hire
    • Free Cooling Hire
    • Ancillaries Hire
  • Service
    • Emergency Breakdown
    • Glycol
    • Service & Maintenance
      • Air Conditioning
      • Chiller Maintenance
    • Spare Parts
    • Water Treatment
  • Industries
    • Agriculture & Farming
    • Automotive & Manufacturing
    • Brewery & Distillery
    • Petrochemical, Oil & Gas
    • Data Centre Cooling
    • Defence, Military & Government
    • Education & Research
    • Facilities Management
    • Food & Beverage Manufacturing
    • Metal Finishing & Tooling
    • Pharmaceutical & Medical
    • Plastics, Rubber & Packaging
  • News & Success Stories
    • Success Stories
    • Latest News
  • About Us
    • About Us
    • Careers
    • FAQs
  • Contact

0333 004 4433

  • Success Stories

Free Cooling Solution Reduces Operating Costs by 50%+ for Packaging Manufacturer

  • April 13, 2022
 

The Client –

Leading Packaging Manufacturer


The Challenge –

Issues Reaching Desired Process Temperature During Warmer Weather


The Solution –

Cooling System Incorporating Chiller, Free Cooler, Pipework & Pumps

A leading manufacturer and supplier of recyclable, flexible packaging solutions contacted us after experiencing issues with reaching their desired process temperature, in warmer weather.

Our Senior Sales Engineer, Mark Hopper explains how we helped them improve the reliability of their process cooling, future proofed their system for expansion and enabled them to make significant energy savings, every year.

Situation

As part of the manufacturing process, a water-cooled chiller with integrated free cooling is used to cool a gear box heat exchanger and cooling for air cooling rings, but in the summer months, the equipment struggles to maintain the required temperature.

In addition to this, full free cooling is only available at -3°C, meaning that a large proportion of free cooling isn’t being taken advantage of throughout the year – resulting in higher energy costs.

Due to the setup, the current system is preventing the manufacturer from growing production capacity and inconsistent process temperatures are creating more wastage and higher energy costs.

Solution

From our initial site survey and consultation, we determined that an additional 160kW of cooling duty was required to maintain the temperature of the gear box heat exchanger and identified that the galvanised pipework was causing water purity issues and blockages.

We designed a new system which included stainless steel pipework (lagged to prevent against thermal losses and condensation), pumps, a new chiller and a standalone free cooler with the existing chiller installed as a back-up.

The process requires the water temperature to be maintained at 16°C, so through the control panel, we set the free cooler to operate when the ambient temperature is up to 14°C, anything over this and a 3-way valve will divert, bypassing the free cooler. The internal chiller pump will then draw water from the process tank and cool it in the evaporator. The water is then driven back to the process by a dual inverter driven pump set.

To ensure a continued operation and cooling to the gear box heat exchanger, we installed the new system alongside the existing one. Once the chiller and free cooler had been commissioned and tested, we connected it to the gear box heat exchanger and removed the old system, including pipework.

To enable further cooling requirements to be easily and cost-effectively catered for in the future, we installed two full sized valves within the pipework.

Results

In just 12 weeks from receiving the enquiry, we had the equipment craned in and the new, more reliable cooling system installed, with capability for expansion.

We estimate that the free cooler will reduce running costs from £89,040 to £41,512, creating a saving of £47,528 per annum, as well as boosting the manufacturer’s green credentials.

Free Cooling solution

Latest Success Stories

Check out industry news, success stories and more.

Aqua Seals The Deal With Retro-Fit Free Cooling

Read More »

Aqua Supports Research Into Origins Of The Universe

Read More »
spot welding

Long Term Hire Provides Worry Free Solution

Read More »

Keeping University Computers Cool

Read More »

Unit 6 Brickfield Lane

Chandler’s Ford

Industrial Estate

Eastleigh Hampshire

SO53 4DP

Registration no. 13262716

VAT No. 382720395

Tel: 0333 004 4433

Email: sales@aquacooling.co.uk

Linkedin Twitter Facebook Youtube

Our Services

  • Chillers
  • Design
  • Boilers
  • Heaters
  • Servicing
  • Parts

Site Links

  • Home
  • Industries
  • News
  • About Us
  • Contact Us
  • Careers
© Copyright Aqua Cooling Ltd 2021. All Rights Reserved.

Terms & Conditions Hire  |  Terms & Conditions Sales & Service  |  Privacy Policy

This website uses cookies We use cookies to give you the best possible user experience, tailored service and functionality. Information from your visit to us may also be shared with our advertising and analysis partners. Click here to read our cookie policy. In order to customize advertising, these partners may in turn combine the information with other information you have provided when using their services.
Accept
Reject All Cookies
Read more