Case Studies

Latest News


Aqua Help Norwegian University Students Keep Cool

The Client –

University Of Stavanger – Norway

The Challenge –

Data Centre Cooling

The Solution –

Rear Door Technology with LPS

Aqua Cooling and their brand partners in Bedfordshire have linked up again to supply ground-breaking Data Centre Cooling technology to one of Norway’s top universities.

Aqua Cooling has delivered its multi-award winning state-of-the art Leak Prevention System (LPS) in conjunction with Bedford-based USystems’ Rear Door coolers to the prestigious University of Stavanger in a deal that consolidates the British firms’ links with the European higher education sector.

The LPS technology, which has won several industry prizes including a 2015 Queen’s Award for Enterprise (Innovation) and recognition by the Institute of Physics (IOP), was designed, developed and patented by Aqua. The Hampshire firm’s ground-breaking design complements USystems’ ColdLogik Rear Coolers, which themselves won a 2013 Queen’s Award for Enterprise (Innovation); the top-flight Norwegian university’s new Data Centre Cooling system combines the benefits of both designs.

This unique composite all-British product offers customers a leak-free guarantee that is transforming data centre cooling applications worldwide. Offering the most energy-efficient low-to-high-density Data Centre Cooling solution currently available, the ColdLogik cooling system has itself attracted many industry and environmental accolades.

By employing the basic scientific principle that water under negative pressure cannot escape through a hole or breach in pipework, the LPS offers Data Centres the option of using water-based cooling systems without running the risk of coolant leakage damage to sensitive electronic data storage equipment.

Mike West, product manager at Aqua DCS (Data Centre Services), said: “The University of Stavanger was looking for an effective cooling system for its Data Centre, and our system’s leak-free guarantee was definitely a key selling point.”

“The Data Centre industry represents an enormous market opportunity for Aqua and USystems — supplying and installing our technology in Data Centres overseas is always exciting, and being involved in the higher education sector is very rewarding.”

The University of Stavanger is ranked as one of Norway’s top ten academic institutions. “Working with such a prestigious establishment has opened the door to an exciting new market in Norway that we hope to develop further in the future,” said Mike.

Aqua’s and USystems’ previous education sector Data Centre deals include cooling system installations at the University of Swansea in Wales and the University of Bath in Somerset.



Aqua Keeps South Western Ambulance Service Ticking Over

The Client –

South Western Ambulance Service

The Challenge –

Data Centre Cooling

The Solution –

In-Row And Rear Door Technology With LPS

Aqua Cooling was called in to regulate the temperature at a Bristol Data Centre that is the beating heart of the south west of England’s medical emergency provision.

The South Western Ambulance Service NHS Foundation Trust (SWASFT) provides ambulance services to the people of Cornwall and the Isles of Scilly, Devon, Dorset, Somerset, Wiltshire, Gloucestershire, and the former Avon area encompassing the cities of Bath and Bristol.

This summer the group turned to Aqua engineers to provide and install a complete Data Centre Cooling system incorporating its patented Leak Prevention System (LPS) in order to ensure the safe and secure storage of its sensitive computerised patient records held at SWASFT’s Bristol headquarters.

Chris Aitken, Data Centre sales engineer at Aqua DCS (Data Centre Services), said: “The SWASFT team was aware of a Data Centre chiller system we had already installed at the University of Bath and realised that a similar, tailor-made solution would be a perfect fit for its own data storage facility in Bristol.”

Aqua’s cooling solution is crucial to the efficient running of the region’s emergency ambulance service — having encountered problems with its previous system, SWASFT was looking for an effective, fail-safe system that would also bring cost and energy savings.

“We’re extremely happy to be working with the South Western Ambulance Service, an organisation that does such excellent and vital work. This opportunity to help ensure that the trust’s operations run smoothly was very exciting — the Aqua team is proud to be a part of such an important service,” said Chris.

Aqua supplied SWASFT with two LPS units, rear door cooler technology and high-performance in-row coolers forming a hot aisle containment system, complete with all the mechanical pipework required for the installation.

Pipework installation began in August, and the system was completed in the autumn — it is now operational and running well. A second phase will see the introduction of a free cooler into the system to increase capacity and redundancy, thereby ensuring optimum energy-efficiency and reducing operating costs.

data centre


Aqua Seals The Deal With Retro-Fit Free Cooling

The Client –

London Based Seal Manufacturer

The Challenge –

Increase Energy Efficiency Of Existing System

The Solution –

Free Cooling Upgrade

For a client running air cooled chiller units to feed their injection moulding hall, the simple addition of a bolt-on Free Cooler to their existing cooling system is forecast to save them over £34,000 in energy costs every year.

Our London based client specialises in producing seals and sealing solutions which are used in the fluid power industry worldwide. Their production facility runs 24/7, so it’s essential that any system downtime is kept to an absolute minimum.

The benefit of adding Free Cooling into a system is that overall power, or energy use, is greatly reduced. Because the lower ambient air temperature is used to cool the process return water wherever possible, the need for mechanical cooling is much less. In addition, by reducing the running time of the equipment you automatically extend its lifetime and lower lifetime maintenance costs. You also gain built in redundancy – if your chiller fails the Free Cooling side can still operate.

The technology within the Free Cooling unit senses both the return fluid temperature and the ambient air temperature. When the ambient is lower than the return water temperature, the fluid is passed through a coil that exchanges the heat in the fluid to the ambient air, using just the mechanical effect required to drive the fans to pull the air through. This means the load is either partially or totally (in the winter months in the UK) reduced – giving partial or full Free Cooling.

Our client already had two chillers on site, to which we added a 280kW Free Cooler. Whilst their system operated on plain, we added a heat exchanger between the system and the Free Cooler, so the latter could run on glycol to prevent freezing during extreme temperatures.

Full system included:

  • 280kW free cooler
  • 280kW heat exchanger
  • Single pump & tank

As the site operated 24/7 the client allocated our installation engineers just a 3-hour window one Monday morning to break into the existing system. Using isolation values, our engineers could then continue with the Free Cooler install whilst production restarted.

Installed in the Autumn, whilst being monitored for the first 3 weeks of running the system operated solely on Free Cooling. Due to the energy savings our client is on target to receive complete system payback in just over one year.

Aqua Sales Manager, Shaun Lancaster, explains; “This is a fantastic example of how retro fitting free cooling can really make an impact when it comes to putting money back on the bottom line. By lowering the plant’s running costs we’ve helped our client increase gross profit without even involving their sales team!”

free cooling


Free Cooling Helps Family Engineering Business Expansion Strategy

The Client –

North Of England Plastics Extruder

The Challenge –

New Plant Machinery Requiring Additional Cooling Capacity

The Solution –

Energy Saving Free Cooling

When a family run engineering company needed to add extra cooling capacity to their plastic extrusion process, it seemed the ideal time to incorporate the energy saving benefits of Free Cooling into their new system.

Our client, based in the North of England, specialises in extruding plastic to produce brush filaments. Due to an increase in product demand they embarked on a project to increase the capacity and speed of their production facility. Key to this strategy was the introduction of an additional extruding line which subsequently changed their cooling requirements.

Historically our client had achieved all the cooling they needed for their production by natural cooling. Put simply, water from a pond outside of their factory was sprayed up into the air. This fountain effect removed the heat from the water which provide sufficient cooling for their existing set up.

However, their upgraded process needed much more accurate temperature control. Whilst giving increased speed and accuracy, the new extrusion machine required a guaranteed 15°C water supply. The existing natural cooling wouldn’t achieve this level of cooling, meaning mechanical cooling needed to come into play.

The Aqua solution included:

  • 136kW air cooled water chiller
  • 136kW free cooler
  • Supply only basis with full technical support
  • Commissioning

As an engineering specialist, our client had all the skills needed to install the equipment in-house, so Aqua offered a supply only basis.

Sales Manager, Shaun Lancaster, explains; “We supplied the equipment and a technical drawing, and the client did the rest themselves. Our engineers visited site for final commissioning and my client knew we were on hand during the install process to help if needed. For me this is a great example of how versatile Aqua Cooling are as a supply partner. We offer full installations with mechanical and electric works but are equally happy to work on a supply only basis.”



Keeping University Computers Cool

The Client –

Swansea University In Wales

The Challenge –

Data Centre Cooling For £450mil New Bay Campus

The Solution –

Hybrid Cooling System With LPS

Hampshire engineering firm Aqua Cooling has successfully installed its state-of-the-art hybrid cooling system for Swansea University in Wales as an integral part of its £450 million new Bay Campus development.

Combined with computer cabinet rear doors, Fareham-based Aqua Cooling’s hybrid adiabatic coolers feature the company’s Queen’s Award-winning guaranteed leak prevention technology (LPS) which allows the effective and worry-free use of a refrigerant-free water cooling system within the sensitive data centre cooling environment.

The hybrid system also represents a significant technological stride forward by providing an effective, cost-effective water-treatment free ambient cooling system that eliminates the emission of excess water spray and standing water. The minimal amount of water that is produced by the cooling process is treated by ultra violet filters incorporated into the system.

Swansea University is the first university to adopt Aqua Cooling’s eco-friendly energy efficient hybrid cooling system in its data centre, although Aqua’s installation project manager, Mike Lloyd-Hole, expects other academic institutions to follow suit.

Mike said: “It has been an incredibly rewarding project. New and returning Swansea students will benefit from this latest application of Aqua’s tried and tested cooling technology, and they can be sure our systems will effectively maintain their learning environments at a comfortable temperature.”

“We are thrilled that our installation will support the university’s drive towards energy efficiency as it increasingly opts for greener operating alternatives.”

“Working with this institution has been an extremely enjoyable experience. We hope this will prove to be the first of many installations in the educational sector as hybrid technology is perfect for use in this setting’” Mike added.

The hybrid adiabatic system is a cost-effective, chemical-free and leak-free cooling solution with an excellent HSE safety record that is designed to regulate temperatures in closed environments such as data centres. Aqua Cooling’s hybrid system in enhanced by the company’s LPS — revolutionary anti-leak technology that not only detects potential fissures in the system and prevents leaks until a more permanent solution can be implemented.



Free Cooling Boosts Energy Savings For Flooring Manufacturer

The Client –

North East England Based Flooring Manufacturer

The Challenge –

Failing Chiller System, Process Water Contamination

The Solution –

Energy Efficient Free Cooling System

For one of our established manufacturing clients, Free Cooling has enabled them to dramatically reduce their operating costs whilst working towards their corporate goal of reducing their environmental footprint.

The client, a leading commercial flooring manufacturer, have invested heavily in both product development and production facilities and they supply their commercial floor coverings to a variety of customers, including hospitals and educational facilities.

Some years ago, Aqua installed a 660kW glycol Free Cooling system to look after the cooling on a second production line which had been installed at their factory. Because their existing production had historically had some issues with contaminated process water, our design team included stainless steel gasketed plate heat exchangers on the second line to overcome this problem. The heat exchangers meant the process and chilled water sources could be kept separate, plus the exchangers were fully cleanable. This had the added advantage of also protecting the integrity of the cooling equipment and reduces maintenance costs longer term.

In 2017 when the original system began to fail, our client was keen to replace their legacy equipment with a second Free Cooling set up.

Aqua supplied an additional 660kW chiller and a 300kW Free Cooler. With both production lines having the same cooling equipment, both new and existing benefited from increased efficiency straight away as power utilisation was less. Their manufacturing now also benefited from built in redundancy – if one circuit should ever fail production would be unaffected. Also, because of the Free Cooler, in low ambient conditions an entire chiller could be stood down with no adverse effect – apart from 75% reduced energy consumption and associated cost savings! Spares were now also common to both lines.
Free Cooling is a relatively simple, but extremely effective concept. Basically, power usage is reduced because lower ambient temperatures are used to cool the return water – rather than the chiller unit. As well as reducing running costs, free cooling helps lengthen the lifetime of equipment as it’s not being utilised as much.

The solution included:

  • Energy efficient chiller & free cooler
  • Bespoke design service
  • EC fans
  • Pumps
  • Plate exchanger
  • Full mechanical & electrical installation

Once the system was installed, the energy savings were quickly evident. The addition of the second chiller to the refrigeration system, gave gains on condenser and evaporator efficiency – on both the new and existing production lines. Aqua Director, Simon Davis, commented: “This is a great example of the benefits of Free Cooling. Our client will save over £12,000 each and every year, meaning the total system will pay for itself in a little over 6 years. Although this is based on the current throughput of the new line, with increased capacity this will drop to under 3 years.”

free cooling


Cooling Technology For The Desert Heat

The Client –

Middle Eastern Finance Group

The Challenge –

Install A Data Centre Cooling System In A Hot Country

The Solution –

Rear Door Coolers

Specialist UK engineering firm Aqua Cooling has completed on its latest Middle East export deal by installing Data Centre Cooling systems in one of the world’s hottest countries.

Supplied to the Bahrain offices of a major Middle Eastern finance group, the job of the Hampshire company’s ColdLogik Rear Door Coolers will be to keep the bank’s computer room cool despite the region’s searing desert heat

The cooling system, which is equipped with Aqua Cooling’s Queen’s Award-winning leak prevention (LPS) technology, also has the capacity to use the local chiller water supply if the community’s distribution network fails in the face of summer air temperatures that can often soar above 50 degrees centigrade.

Designed to revolutionise traditional data centre cooling methods, ColdLogik heat exchangers are fitted as back doors to computer cabinets that cool the heat at source before passing the air back into the data centre at the correct temperature.

Mike West, Data Centre Cooling Products Manager at Aqua Cooling’s Fareham office, said: “It’s great to see our award-winning systems installed in such an exciting location, and an added bonus that they are capable of benefiting the local community as well as our new banking client.” he said.

“As Aqua Cooling’s latest export order to the Middle East, this is a ground breaking project. Our ColdLogik system is certainly efficient enough to deal with the Middle Eastern climate and offers significant size and operating cost advantages.”

“Hopefully the success of this installation will pave the way for further opportunities with other clients in the region and beyond,” added Mike.

This latest Aqua Cooling installation in Bahrain is designed to keep its banking client’s data centre cool and operating at an optimum room temperature of 24 degrees centigrade. Capable of chilling loads of up to 25kW (max) 10kW nominal per cabinet, the ColdLogik Rear Door Coolers are compact and efficient, effectively reducing the minimum size requirements of buildings that house them.



Aqua Link Up With Arthur McKay

The Client –

Lloyds Bank In Halifax

The Challenge –

3.4mW Project For A Comfort Cooling System

The Solution –

Cooling Tower Installation

Aqua Cooling’s latest cooling tower installation centred around a 3.4 MW project for the comfort cooling system at Lloyds Bank in Halifax.

The Lloyds Banking Group commissioned Arthur McKay Building Services with an initial design criteria that specified inlet and outlet temperatures of 37°C and 27°C respectively, a 293.8m³/h flow rate, and a wet bulb temperature of 20°C.

In response, Aqua supplied and installed a 3.4 MW cooling system, comprising four stainless steel SPX Marley cooling towers. Aqua Cooling is the approved UK distributor for the Marley range and the system was designed to incorporate spare capacity to allow maintenance to be carried out. The system’s overall capacity is in excess of 130%, so even with one tower out of operation the remaining three will still provide 98.4% capacity.

The towers, from Marley’s NC range, have been supplied in stainless steel to increase the versatility and life-span of the installation. “The NC model combines high capacity with high efficiency and a smaller profile, making it the ideal choice for larger applications”, explains Peter Fowles, Aqua’s Projects Engineer.

The NC towers have state-of-the-art components in a time-tested tower design which has proven itself again and again in installations world-wide. The NC achieves lower operation costs and energy usage, accomplishing ASHRAE 90.1 efficiencies up to six times more than required.

Lynne Allison, from Arthur McKay Building Services, commented: “The equipment was supplied and installed to a very good standard and met with the client’s requirements. Aqua Cooling provided very sound technical and project assistance to ensure that the overall project went very well and to the client’s satisfaction.”

cooling tower

network computing awards

Network Computing Awards 2018

Aqua Group’s unique Leak Prevention System (LPS) has been shortlisted as a finalist for Data Centre Product of the Year at the 2018 Network Computing Awards.

The Leak Prevention System has already won a Queen’s Award for Enterprise: Innovation and an Innovation commendation from The Institute of Physics (IOP).

Simon Davis, Director and Founder of Aqua Cooling Solutions designed the LPS technology which is based on a simple principle of physics. Simon explains; “At the heart of our LPS is a Venturi tube which turns water pressure from positive to negative. This simple change in pressure prevents water escaping from any damaged pipework, hoses or connection. Unlike competitor products, this isn’t a leak detection system but gives guaranteed leak free operation. Energy savings of up to 98% have been proven when compared with traditional data centre cooling set ups.”

The LPS enables clients to gain all the benefits that a water-cooled solution can offer the data centre environment but with complete peace of mind. It can also be fully integrated with the majority of data centre cooling products in the marketplace, whether that be rear doors, in rows or CRAC units.

Winners will be announced during an awards dinner in London in March. The dinner will take place at The Radisson Blu Edwardian Hotel on the evening of 22nd March.

To vote go to


Anglian Windows Carbon Home Improvements

The Client –

Windows And Doors Company

The Challenge –

Improve Energy Efficiency And Costs At Production Sites

The Solution –

Resize Chillers And Add Free Cooling

Anglian may already be well known for producing energy efficient windows and doors, but over the last year they have been taking a detailed look at the energy efficiency and related costs at their own production sites. Anglian employed specialist energy consultants Energy 2000 to establish an energy management programme for the company.

Detailed scoping studies were undertaken at six main sites to establish the current energy usage habits, with every significant item of manufacturing equipment being monitored and logged. Reports were then produced identifying all potential energy saving measures, from no cost/low cost recommendations through to high capital expenditure projects.

It was identified that the water chilling plant for the plastic extrusion process was consuming a large proportion of the Norwich site’s total usage and further investigations confirmed the inefficiency of the current plant. A recommendation was put forward to replace the chilling plant with the introduction of a “free cooling” process to meet current demand. In addition, new chillers were sized to give an extra 50% capacity as provision for future expansion.

Aqua Cooling Solutions were recommended by Energy 2000 and were chosen to provide the equipment and to install and commission the 1.6 MW system. The integral free cooling facility uses the ambient air to cool the process water as soon as the ambient air temperature falls below water temperature returning from the extrusion machines.

The system has been closely monitored since start-up in August and it is calculated that Anglian will save over 850 tonnes of carbon per annum, equating to a financial saving of approximately £175,000 per year. The entire cost of the new cooling system will be recovered by energy savings made within just the first two years of operation.

Chris Dixon is Engineering Director at Anglian Windows. “With energy costs beginning to spiral upwards, and with our commitment to reducing our Carbon Footprint, we needed to implement a comprehensive Energy Management Programme. We accepted that this required specialist skills and, therefore, made the decision to outsource. Energy 2000 were selected as our partner because of their positive approach, cost effectiveness and their commitment to work with, and not just for, Anglian. We have enjoyed a very successful first year with Energy 2000. Savings have been identified and prioritised and, with their pro-active approach and Aqua’s equipment, we will continue to drive down our energy costs and reduce our carbon emissions.”

Aqua’s Director, Kevin Lancaster, comments: “We were delighted to be recommended by Energy 2000 for the Anglian Windows project. Aqua are committed to coming up with innovative, energy efficient solutions for clients and the Anglian system is an excellent example of how the free cooling concept can have a considerable impact, both from an environmental and financial point of view, in a relatively short space of time.”