blow moulding

Free Cooling Upgrade Saves £70K Annually

The Client –

Plastics Blow Moulder


The Challenge –

Energy Efficient Upgrade


The Solution –

Complete Cooling System Design

For a client with a legacy cooling system, a full system upgrade gave them the opportunity to benefit from the latest in energy efficient cooling technology.

Our client, an end user, specialises in plastics blow moulding and initially asked Aqua to carry out an energy evaluation on their existing factory set up. Our engineering team then designed an upgraded system with estimated annual costs savings from reducing overall energy consumption. When it comes to energy calculations, we are completely transparent and pride ourselves on living up to our predicted savings.
The suggested upgrade centred around utilising highly efficient free cooling technology, alongside inverter driven pumps. New chiller units were added to two production lines – on the injection moulding side and the blow moulding. Based on our client’s annual production schedule, energy cost savings were forecast at over £70,000. The free cooling also reduces the run hours on the chiller units, increasing their overall life expectancy.

An additional advantage for our client from moving to the new system was the warranty, giving them peace of mind for the years ahead.
The full solution included:

  • Energy efficient design review with energy calculations
  • Free cooling chillers
  • Inverter driven pumps
  • Mechanical installation & final commissioning
  • Warranty
  • Aftersales support

“Our client had become exasperated with their old system, experiencing long lead-times from the manufacturer when they needed to source replacement parts and then discovering some spares had become obsolete. That said, I think the prospect of a full system upgrade initially made them nervous because of the anticipated costs involved. However, our energy review quickly established that upgrading their equipment would bring them so many advantages. As well as a very quick payback – less than 2 years – they will make significant energy and cost savings every year” explains Aqua Sales Manager, Shaun Lancaster.

wc brewery

Aqua Comes Up Trumps for Wild Card Brewery

The Client –

Wild Card Brewery, London


The Challenge –

Relocation And Production Expansion


The Solution –

Cooling System Design, Supply & Install

For an award-winning London based brewery, a move to new premises gave them the opportunity to install a brand-new process cooling system, complete with built-in heat reclaim.

Wild Card Brewery, based in Walthamstow, East London, was founded in 2012. Within just 5 years Wild Card had 2 award winning beers to their name and currently supply supermarkets, pubs, bars and restaurants throughout the UK. They quickly realised that demand for their products was totally outstripping production and moved to new premises, giving them the potential to double their capacity.

Aqua designed and installed an energy efficient temperature control system for the new facility. The system chills the brewing tanks to sub 10°C once the fermentation stage of the process is complete. The chiller unit was designed with built in waste heat recovery, which is achieved by means of a desuperheater. The waste heat created during fermentation is subsequently reclaimed and used at the earlier “mashing” stage which requires water at 70-75°C. The heat reclaim process can achieve 50-55°C which means only a small amount of energy is then needed to top up the temperature to the required 70-75°C.

The new system’s energy credentials enabled Wild Card to successfully secure a £5,000 capital contribution from the Carbon Trust’s Green Business Fund. In addition to this, Aqua’s system is expected to save the brewery £3,000 each year in energy savings.

The full solution included:

  • Chiller with desuperheater for built in heat recovery
  • Glycol tank
  • Pumps
  • Individual temperature control systems for each tank – 12 in total
  • Bespoke design service
  • Support with a Carbon Trust Green Business Fund capital contribution application
  • Full installation – including electrical and mechanical works

For Wild Card the system has proved a real success. Head Brewer, Jaega Wise, explains “We’re really pleased with the new system at Lockwood Way, and after starting a crowdfunding campaign to facilitate our move, the annual savings are invaluable to us as an SME. The fact that Aqua are an approved supplier to The Carbon Trust and could help us secure an additional £5,000 funding was invaluable. We’re now looking forward to producing lots more Wild Card beer for everyone!”

carbon trust

edible oils

Tactical Hire Completes The Solution

The Client –

Food Processor


The Challenge –

Bottling Process & Seasonal Cooling


The Solution –

Capital Chiller Sale & Hire Solution

With sales, hire and service divisions, Aqua Group is a total solution provider, offering an array of products and services, depending on a customer’s specific temperature control requirements.

For a food industry client, their relationship with Aqua has spanned a decade, with the supply of both permanent and temporary solutions, along with maintenance support.

The client specialises in processing and packaging oils for the food sector, including market leading brands of olive oil, seed oils and baking fats. Aqua were initially commissioned to supply a chiller—based cooling solution for their Sidel liquid packaging system. This was designed, supplied and installed onto their blow moulding line.

For most of the year, the raw oil product can be taken straight from holding tanks into the bottling plant and packaged as appropriate. However, in the warmer summer months, the oil must be cooled prior to bottling. It’s vital to ensure the oil is processed in the correct way, otherwise the overall quality of the oil and its integrity can be compromised which can also affect its shelf life.

Over time our client became concerned that, should temperatures rise significantly during the summer, their production could be disrupted. So Aqua subsequently designed a tactical chiller hire strategy to ensure production could continue, regardless of the ambient temperature. The strategy involved supplying two 50kW rental chiller units, which are situated close to the holding tanks, and can be called on as and when required. The chillers cool the oil within the tanks until it’s achieved the optimum temperature for transferring to the bottling plant. Once temperatures drop again, the units are simply taken off hire and the bottling process carries on as before.

“For me this is a fantastic example of how Aqua builds long term strategic relationships with clients” explains Shaun Lancaster, Aqua Sales Manager. “For Aqua It’s not just about the one-off initial sale, but it’s supporting and working in partnership with our customers over the years as their business develops and changes. As a total solution provider, we can support our customers in so many ways, whether they need a system upgrade, a temporary fix or ongoing maintenance and service support.”

edible oils

Stainless Steel Marley Solution Drives Production Forward

The Client –

Automotive Component Manufacturer


The Challenge –

Legacy Cooling Tower System


The Solution –

Centralised Cooling Plant

As an automotive component manufacturer, our client had historically relied on cooling towers to provide cooling to their hydraulic oil and spot-welding process. However, internal health & safety checks were frequently highlighting potential problems with their aging cooling towers, leading them to consider replacing the equipment.

Aqua designed a complete centralised cooling plant, which could feed the different stages of their manufacturing process. The system incorporated a cooling tower from the SPX Marley range which was constructed from 304 stainless steel. The anti-corrosive properties of 304 stainless are renowned – giving reliability and longevity to the product as well as overall peace of mind for the client.

Our design team selected a crossflow configured tower, giving energy saving benefits within a small footprint but with a relatively low maintenance requirement. Inspection, servicing and maintenance is made easier by large access doors. The tower’s plenum region is generous, which means it’s quick to carry out a visual inspection of the tower’s basin, as well as the internal structure and mechanical equipment.

The cooling tower was also designed with a quiet fan operation, but again with aluminium fan blades.

In addition, we built a pump set that could offer run and standby, using Danfoss inverters to ensure automatic change over and eliminating the need for manual intervention. Our client had already successfully trialled an inverter on their existing pump, so they were only too aware of the energy savings this offers. Now, as well as gaining efficiency, they were also adding reliability to the system.

Full solution included:

  • Design and project management service
  • Cooling tower, inverters and pump
  • Delivery, installation and commissioning

“Our client now has a central cooling plant which can provide capacity for all of their different production phases. As well as immediate energy savings from the newer technology, our client now has reliability and longevity built within their system, future proofing their business for the years ahead”, explained Aqua Sales Manager, Shaun Lancaster.

cooling tower

dairy plant

Propane Chillers Future Proof Dairy

The Client –

Dairy Processor, North Of England


The Challenge –

Future Proofed Cooling System


The Solution –

Propane Chiller System Install

Propane chiller technology has ensured a dairy plant in the North of England is not only highly energy efficient but also extremely environmentally friendly.

Our client provides goats’ milk to supermarkets across the UK as well as processing the raw milk into a range of products, including yoghurt, cheese, butter and cream.

When Aqua were commissioned to design a replacement cooling system for their dairy processing facility, future proofing the dairy for the years ahead was a key driver in the decision-making process. This, coupled with the current phase-out of hydrofluorocarbons (HFCs), led to R290 propane being their refrigerant of choice.

New F-Gas regulations came into effect initially in 2015, designed to control emissions from fluorinated greenhouse gasses (F-gases), including HFCs. The EU’s overall aim is to cut F-gas emissions by two-thirds by 2030, when compared with 2014 levels. By 2020 the use of virgin HFC refrigerants with a Global Warming Potential (GWP) of above 2500 will be banned. This includes previously mainstream refrigerants such as R-404A and R-434A.

Aqua can supply a range of chillers that run on the refrigerant grade propane, R290. Propane refrigerant is 100% natural, has excellent thermodynamic performance, is non-toxic, has a GWP of just 3 and a zero Ozone Depletion Potential (ODP).

The new dairy system looks after the cooling for the entire facility, from the raw milk being offloaded from tankers, through to the processing and bottling stages. Aqua also designed a bespoke galvanised steel gantry frame and staircase, allowing the new equipment to be sited at high level with the area below still accessible. As well as achieving an extremely efficient and high performing system, our client has dramatically reduced their overall carbon footprint as a business.

The full solution includes:

  • 2 x R290 propane chillers
  • Process tank with hot & cold section
  • Inverter driven process pumps
  • Full design, mechanical installation & commissioning
  • Preventive maintenance contract

“R290 refrigerant is becoming increasingly high profile, especially with clients within the food & beverage sector” explains Aqua Group’s Mike West. “With all the regulatory changes over the last few years, choosing the most suitable refrigerant can be a minefield for both clients and potential customers. It’s our job to make that more straightforward and transparent for customers, helping them to achieve the most efficient and energy effective solution for their specific needs.”

propane chiller

salmon

Bespoke System Helps Scottish Salmon Industry

The Client –

Scottish Salmon Producer


The Challenge –

Expansion Of Production Facility


The Solution –

Custom Designed Cooling System

When a seafood company looked to expand their salmon production across Scotland, Aqua were commissioned to design a fully bespoke cooling system to upgrade their existing facility.

The client, one of the worlds’ leading producers of farmed salmon, was looking to upgrade their salmon hatchery in a drive towards longer term sustainability and efficiency. The new hatchery would not only dramatically increase the number of employees on site but also improve their ability to grow out smolts which would then supply their network of Scottish sea farms.

A smolt is a young salmon and refers to the development stage before full adulthood. The salmon start their life in hatcheries or loch farms before moving on to sea farms where they grow to full adulthood.
Aqua supplied a 1,550 kW custom designed system which worked on the principle of water being taken from a local river, into a large buffer tank. This water is circulated through two chillers which are specially designed with cupro-nickel water cooled condensers so they can operate on river water. The chillers then supply four plate heat exchangers to separate the salt water from the chilled water and to protect the livestock. Each of these heat exchangers is associated with an independent tank which either houses the very small salmon fry or the larger smolts.

As well as keeping the tank temperature at the optimum for the well-being and development of the salmon, the system is designed for maximum energy efficiency. Each chiller has 6 highly efficient multiple scroll compressors which are installed in 3 fully independent circuits with 2 compressors – giving 6 separate capacity stages. They each also have triple circuit shell & tube evaporators as well as shell and tube condensers. Each chiller unit has a COP (Coefficient of Performance) value of just 5.11 under full load conditions.

The full solution included:

  • 2 x 770kW water cooled chillers
  • 8,000 litre polypropylene buffer vessel
  • IE3 motor, run and standby pump system
  • Energy efficient design – including R410a refrigerant
    and COP value of 5.11 for compressor under full load conditions
  • Reduced noise specification – including
    acoustic jackets on chiller compressors
  • Centralised control system
  • Full design service plus electrical and mechanical installation

The versatile design of the cooling system means that during the warmer months when the ambient temperature is higher both chiller units can be fully operational. But, during the cooler Spring & Autumn months the system can simply reduce to medium/low load. In this scenario just one chiller needs to operate – massively increasing operating costs and efficiency, by turning the pump motors off – yet the control system will rotate between both units at start up so that they are both used equally.

Ian Clynes, Aqua’s Northern Project Manager, explains; “Scottish salmon has a great reputation around the world and the aquaculture process is vital to the country’s economy, so this was a great project to be involved with. The unique system design is a fantastic example of Aqua’s ability to engineer energy efficient solutions that can really make a difference to clients’ businesses.”

marine

washing machine

Adiabatic Cooling Puts A Spin On Things For Home Appliance Manufacturer

The Client –

Home Appliance Manufacturer, UK


The Challenge –

Hydraulic Cooling Upgrade


The Solution –

Adiabatic Cooling System

Built in redundancy and energy efficiency are often key factors for clients when they’re considering upgrading their cooling equipment. This was exactly the case for a client who wanted to replace an aging air-cooled chiller system which provided hydraulic oil cooling to their manufacturing process.

Our customer is a market leading manufacturer of home appliances, including a range of washing machines and tumble dryers. In addition to being old, their existing chillers ran on R407C refrigerant, which limited their energy efficiency potential.

During the manufacturing process, our client uses a cold press to produce component parts. In very basic terms, a sheet of metal is inserted between two metal plates. A hydraulic system then creates a sheer force which presses the required shape into the metal sheet.

Our in-house design team removed 3 chiller units from the existing cooling system, replacing them with a single adiabatic cooler. One larger chiller unit was retained as a back up option. Moving to an adiabatic system meant the required cooling capacity could be achieved without the need for a refrigeration system. As well as decreasing electrical power consumption, this has the added benefit of removing moving mechanical parts, so reducing running cost and future maintenance costs.

A shell and tube heat exchanger was also included, taking the hydraulic oil one side and cooling fluid on the other.

The adiabatic cooler supplied had 5 fans, so if 1 should ever fail, the cooling function would continue unaffected. The fans can also be replaced whilst the unit is operational, so you gain built in redundancy.

The full solution included:

  • 250kW adiabatic cooler with EC fans
  • Shell & tube heat exchanger
  • Process pumps, inverters and pressurisation unit
  • Mechanical installation, pipework and commissioning

“This project is a great example of how a relatively simple system upgrade can achieve a multitude of benefits for clients. For this customer their total cost of ownership really reduced, and they gained peace of mind that their process now incorporated redundancy on the cooling side” explains Aqua Sales Manager, Shaun Lancaster.

adiabatic

adiabatic

Adiabatic Re-Design Overcomes Site Challenges

The Client –

UK Automotive Component Manufacturer


The Challenge –

Failing Adiabatic Cooler + Access Challenges


The Solution –

Replacement Adiabatic With Reduced Footprint

Our design team are used to overcoming access restrictions on sites but an extremely narrow passageway and overhead cabling on a recent project posed a real challenge.

The client, a leading manufacturer and distributor of automotive components, tasked us with replacing an old, failing adiabatic cooler. Removing a legacy unit and replacing it with new equipment is relatively straight forwarded most of the time – but on this occasion things were going to be trickier! A narrow walkway restricted access and overhead electrical and telecommunication cables ran above the site’s fencing, meaning using a traditional HiAB lift wasn’t going to be an option.

Whilst our client wanted a like for like replacement, our engineers used the initial design phase as a chance to reduce the dimensions of the new adiabatic cooler, giving more room for manoeuvre – quite literally! Whilst the new unit could achieve the same duty as the existing, our design team managed to make it significantly smaller in size.

Aqua supplied a 500+kW adiabatic, working on a water supply temperature of 30+°C, with a return temperature of 43.4°C, with a wet bulb of 19°C. Fluid was 25% ethylene glycol/water. By changing the configuration of the unit’s fans, the footprint was considerably reduced.

Whilst replacing the old adiabatic with the new unit wasn’t easy, positioning and installation was made much easier by the unit’s reduced dimensions. It also made navigating the restricted access ways a more straightforward task.

The full Aqua solution included:

  • 505kW adiabatic cooler
  • Bespoke design service
  • Mechanical disconnection & disposal of the legacy cooler
  • Full delivery and installation
  • Hoses and related ancillaries

“This installation is a great example of how important the initial design phase can be” explains Aqua Sales Engineer, Bhaskar Choudhury. “Once we visited site the access and delivery restrictions became clear and the work our design team then did at that early stage made life so much simpler when it came to the final install, saving our client both time and cost.”

adiabatic

gauges

Bespoke Design Solution Overcomes Space Challenge

The Client –

UK Industrial Gas Manufacturer


The Challenge –

System Upgrade, Within Restricted Footprint


The Solution –

Built To Order Air Blast Solution

Our client specialises in the manufacture of industrial gases which are used across several sectors including food & beverage, medical and petrochemical, to name just a few. As well as more widely known gases such as oxygen, nitrogen and helium, some speciality gases are manufactured for specific processes.

Aqua were tasked with upgrading the cooling to the compression system used in the gas manufacturing process. As production has increased over recent years, our customer was keen to replace their existing dated equipment with new whilst increasing the system’s cooling capacity at the same time.

Limited by the footprint available, our design team worked on a specially manufactured air blast cooler design to ensure the new system would fit within the existing space. Along with the cooler, sits pumps, pressurisation set, expansion and header tanks. Using 3D imagery, our designers ensured all the equipment would fit into the restricted footprint.

The system is sat on a skid, with a control system bespoke to the client’s specifications. The skid design enabled the entire system to be delivered to site and connected, keeping installation work and disruption to production at a minimum.

The bespoke 490kW capacity air blast cooler, incorporates EC fans and the pumps have inverter drives, maximising overall energy efficiency. It’s anticipated that energy saving will be over 50% compared to the legacy cooler that was in situ.

The full solution included:

  • Custom skid design
  • Bespoke equipment manufacture
  • Air blast cooler, pumps, pressurisation set and tanks,
  • Bespoke control system

In addition, because the air blast cooler is in a coastal environment, final specification included marine paint and coated fins to eliminate any risk of corrosion.

air blast

simons array

Aqua Supports Research Into Origins Of The Universe

The Client –

University Of California


The Challenge –

Cooling In Chile’s Atacama Desert


The Solution –

Air Blast Radiator Technology

The search for the origins of the Universe is being advanced with the help of Air Blast Coolers supplied by award-winning Fareham engineering firm Aqua Cooling.

For the past five years the specialist chilling equipment has been used in a multi-million dollar astronomical observatory in Chile’s Atacama Desert; now additional units have been fitted by Aqua Cooling as more telescopes are brought in to search the skies for a particular type of cosmic wave that experts believe was created immediately after the Big Bang.

Scientists at James Ax Observatory are undertaking an experiment into the polarisation of background radiation in a project named Polarbear and have already published significant findings. The facility is positioned 5,200m above sea level — it is one of the highest observatories in the world — and is manned by a team of researchers from several US universities including the University of California, San Diego, alongside several international partners.

The scientists’ aim is to prove the theory of inflation – that the Universe grew rapidly after the Big Bang, inflating like a balloon. Key to proving the theory is detecting a certain type of background radiation, which the Ax Observatory has already done. The team’s success has led to funding for an array of three telescopes to move the research forward.

Aqua Cooling was asked to supply more of its Air Blast radiators to support the new Simons Array of telescopes. Cooling is essential because the receivers on each of the telescopes must operate at cryogenic temperatures. This is achieved using commercial helium gas-cycle refrigerators and these refrigerators have compressors that are cooled by Aqua Cooling’s radiators.

“The original Polarbear experiment has been running off an Aqua radiator for more than five years,” explained Nathan Stebor of the University of California, San Diego. “We needed more radiators to accommodate the new receivers coming online for the Simons Array and Aqua’s solution was perfect in terms of simplicity and compatibility.”

Matt Goodman, Key Accounts Manager at Aqua Cooling, said: “Playing a part in the fascinating work going on at the James Ax Observatory demonstrates the versatility of our chilling equipment and our ability to deliver projects in some of the most remote areas of the world.”

“We have been working closely with the University of California team to add the capacity they need and build upon our existing relationship. We shall be following the next stage of their research with great interest.”

simons array

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