Chilled Water System Improvements for Global Plastic Component Manufacturer

Essentra Components manufacture parts from packaging and fluid handling to moulded plastics and hardware. They operate over 100 injection moulding machines at their large site in Oxfordshire.

Their machines utilise Chillers and V Bank Airblast Coolers to provide cooling to the tools at 14°C and to hydraulic oil at 20°C. Minimising downtime is crucial to their production, so they need a maintenance partner that they can rely on to maintain and optimise their chilled water system and equipment.

The situation

The manufacturing site required a reliable and supportive partnership with a reputable provider of high-standard technical support, maintenance, and servicing.

The use of mixed metals in the internal factory pipework had caused corrosion, which led to the poor quality of water running through the system, damaging the pipework and causing leaks.

If closed-loop systems or the water used within them are poorly maintained or left untreated it can lead to problems that will affect energy usage, cost, asset performance, and reliability. Specifically, these problems include corrosion, fouling, biofouling, and scaling to a lesser extent unless there is significant water loss requiring additional make-up water.

These issues were resolved in the recent past by adapting their cooling water system from a closed-circuit pressurised system to an open tank system – making it easy to monitor the quality
of the water and add treatment as needed.

The solution

We are providing the site with technical support, maintenance and regular servicing of the equipment. This includes cleaning and ushing the dual filter arrangement to ensure clean and treated water is provided – protecting the system components and minimising the risk of downtime.

You can view the full Essentra Components case study online.

To discuss how we can help improve the efficiency and maintenance of your chilled water systems, please call us on 0330 404 3228 or contact us online.

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