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.

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wheels

Innovative Adiabatic Cooling System Keeps Wheel Production On Track

The Client –

Alloy Wheels Supplier


The Challenge –

Re-specify Cooling Equipment


The Solution –

Adiabatic Cooling Solution

A state of the art Adiabatic Cooling system has helped to expand and transform alloy wheel production for one of the UK’s largest alloy wheel suppliers.

Based in the Midlands, our client designs and manufactures the wheels which are then supplied to the automotive market worldwide. They have worked with several the market leading vehicle brands and supply the motorsport sector.

Aqua supplied two Adiabatic Cooling systems, one of the key design benefits of the system was the ability to precisely control the exact amount of Adiabatic spray required by the process, reducing water loss and making subsequent savings on water consumption. Energy savings and overall efficiency are a real focus of the system, which is further enhanced by incorporating inverter pumps and EC fans.

One Adiabatic unit has been installed on the factory’s hydraulic press line and provides cooling for the quench tank. The second is on the diecasting line, cooling the process after the raw material has been injected into a mould under high temperature. Previously the line operated with air cooled tooling, but this was upgraded to a water-cooled system as part of the ongoing expansion programme.

Sales Director, Simon Davis, explains; “Aqua were initially approached because the client’s original supplier had miscalculated the cooling requirement of the production process, resulting in the wrong equipment arriving at site. We were asked to visit site, re-specify the equipment and supplied and installed the complete system. Since the initial installation Aqua have won a second contract for further work which I hope is testament not only to our product offering but also our customer service.”

The solution included:

  • 400kW and 700kW adiabatic coolers
  • Inverter pumps
  • DC driven adiabatic spray pumps
  • EC fans
  • Energy saving system design

With their new Cooling system in full operation, our client is now well placed to continue their ongoing strategy to be the major driving force in alloy wheel production across the globe.

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