Bolton based plastics manufacturer Norlin Polymers (UK) Limited
Replacement cooling system
Sustainable adiabatic cooling system
Temperature control is key to the plastic manufacturing process. It is used in numerous ways, from melting the raw material, through to extrusion, injection moulding and polymerisation. Aqua were asked to design a cooling system for a client operating with the sector, who was using mains to drain cooling. Their legacy set up was proving unsustainable, both from a cost perspective as well as environmentally due to the volume of wastewater and utility costs.
Situation
As a leading manufacturer of technical & specialised polymer compounds, Norlin Polymers supplies the medical & pharmaceutical sector across Europe. They extrude a specialist plastic material which is then used for applications within the industry.
The extrusion process is akin to that used widely within plastics processing. The raw plastic material is melted, blended, and forced through a dye which results in polymer strands. Their process differs when it comes to the cooling of the strands and maintaining the cooling water to set temperature.
The mains to drain system used cold towns water to fill the extrusion baths. The water kept the bath cold, and it was regularly replenished for hygiene reasons. The client controlled the fill/overflow from the mains tap.
Having recently acquired a new design of water bath, one which could be equipped with a pump and heat exchanger, they were able to consider adding cooling equipment to the process and moving away from the manual system.
Solution
After establishing that the heat exchanger on the bath could provide sufficient cooling with water temperatures of 25°C and 35°C, we suggested using a system incorporating adiabatic cooling.
Adiabatic coolers are an excellent choice because they are low maintenance, cost-effective and a highly sustainable option if you are working with water temperatures of 25°C+. Aqua’s adiabatic units achieve a great balance between water usage, fan speed and load. They reduce energy, significantly save water, and minimise environmental impact.
“The adiabatic system we designed, is able to run several extrusion lines, with the ability to operate different machines at different temperatures, to suit our clients’ manufacturing requirements” explains Aqua Regional Sales Manager, Mark Whittaker.
Any fluctuation in cooling will impact on product quality, so system control is important. Aqua’s design incorporates a central control panel, which monitors both the adiabatic cooler and the pump. There is also a temperature controller with an external probe on the tank return pipe and a 3-way valve. This ensures the temperature is easily controlled and kept consistent. The addition of a tank ensures easy filling and dosing of the system.
Results
“With this upgrade our client has future proofed their business” continues Mark. “Without the changes they were faced with rising costs which would either have limited profitability or caused them to have to increase their sale price and pass the pain onto their buyers.”
“Aqua were the perfect partner for Norlin. They provided design support where we needed it, expert installation, and after-sales care. The adiabatic system simultaneously helps us achieve both production requirements and our sustainability objectives” explains Norlin’s Commercial Director, Jonathan Holland.
To discover how adiabatic cooling could help your business, chat with the team on 0333 004 4433.
Global chemical processor
Production downtime due to variable temperature rise
Free cooling chiller based process cooling solution
Temperature control plays an important role when managing chemical reactions and the stability of chemical compounds. Aqua were approached by a global chemical processor to design & supply a cooling system for their product development division.
Situation
As a manufacturer of speciality chemicals, including silicone emulsions & compounds, our client was facing challenges with the development of a new product. The production process involved taking an aqueous emulsion and mixing it within a batch tank. The mixing and moving causes an exothermic reaction, which releases heat and increases the temperature of the solution.
This temperature rise was proving problematic, slowing production, and creating unwanted downtime. On occasion, production was having to be stopped mid batch cycle, resulting in product and hours of production time being wasted.
Solution
Aqua designed, supplied & installed 3 x Aqua EcoPro chillers, configured on a run/run/standby basis. All units were installed on the roof of the production facility, optimising available space.
The system is designed so that, in normal operation, the three units work on a cycle, so their running hours are similar. They run on a part load basis, dissipating the unwanted heat together. If the heat load exceeds the capacity of a single chiller, a second will start, with the third available if needed.
The run/run/standby configuration gives the system built in redundancy. In the very unlikely event that a unit should fail, the control system will ensure another unit takes over. This leaves production running as planned, with no risk of downtime.
By installing Aqua EcoPro units, the system also benefits from fully integrated free cooling. Not only does free cooling dramatically cut energy consumption, it also substantially reduces operating costs and extends equipment lifetime.
Free cooling uses the natural air to cool, rather than the need for mechanical refrigeration. The outside ambient temperature dictates whether partial or full cooling is possible, but both have a significant impact on carbon footprint and energy usage. The Aqua EcoPro units also operate on R454B, which has a low global warming potential (GWP) value and is a much more sustainable refrigerant than commonly used options like R410A.
Results
“My client has gone from having no process cooling, to having a state of the art, reliable system with built in redundancy. This gives them complete peace of mind, safeguarding their production strategy against delays and downtime” explains Will Coles, Aqua Area Sales Manager.
“In addition, for 72% of the year, they’ll benefit from a level of free cooling. The new system will really make a difference day to day, and they’ll also make some impressive savings along the way!”
If you’d like support with your next temperature control conundrum and to find out how free cooling chillers can help your business, call the team on 0333 004 4433.
Metal finishing OEM
Achieving reliable temperature control
Fully customisable temperature control system
Dependable temperature control is key to the success of metal finishing processes. It ensures the manufacturing process stays operational and on schedule, as well as maintaining consistency and quality of the final product. Ben Newman, our OEM Specialist, worked with Aqua’s internal design team to devise a customisable temperature control system for a new OEM customer operating within this sector.
Situation
Metal, or surface finishing, refers to a range of industrial processes which alter the surface of metal. It covers techniques such as powder coating, galvanising, and anodising, to name but a few. Ben’s OEM client supplies plant equipment and ancillaries to end clients within this industry.
From time to time, these end clients expand their businesses, acquiring new or larger plant or replacing their existing process equipment. If the equipment does not work correctly, downtime, reduction in production and quality issues can result, all of which they’re obviously keen to eliminate.
A typical plant system consists of several baths that products are dipped into, either cleaning up, degreasing, or giving different finishes to the surface of the product. These baths need to be kept at a pre-set temperature for optimum results, otherwise the fluid within them could overheat and evaporate, which puts the process – and the finished product – in jeopardy.
Solution
Ben and the team proposed a solution which would be easily customisable depending on the specific equipment and operating conditions that the OEM client was supplying.
Essentially, the fluid in the baths recirculates around a plate heat exchanger and the process is cooled by a chiller. For example, one end user had a 70kW thermal heat load and needed a coolant supply temperature of -8°C, with the process feeding 3 separate tank systems. For this scenario we supplied a single chiller from our Aqua Pro range and the coolant from it is fed to all 3 tanks. Utilising a single chiller for multiple processes keeps the footprint of the installation to a minimum too.
Aqua Pro chillers are particularly suited to manufacturing applications such as surface finishing. The chillers benefit from innovative evaporator and condenser design and are well equipped to stand up to the conditions that industrial environments can bring. They’re also have great eco credentials, making them highly efficient too.
The ease by which our solution can be customised was a big plus for our OEM. Whether they’re selling single or multiple tank arrangements, the temperature control system can be adapted accordingly. Depending on the end user’s site conditions, enhancements can easily be made. For example, if the baths are being used in an aggressive, heavy industrial environment, the condenser coils can be pre painted to give added protection. Performance modifications can also be incorporated, for example variable fan speed control, enhancing energy efficiency and reducing electricity usage and cost.
Results
“Once installation is complete, our OEM customer now has a very reliable temperature control system which can be scaled up and enhanced depending on their client’s individual requirement” explains Ben. “As an OEM, speed of response and ongoing service support are paramount and really valued. So, as well as our solution, the fact that we could assure the client of 24/7 nationwide support, was important.”
If you’re an OEM looking for support with temperature control, contact Ben Newman, Aqua’s OEM Specialist on 0333 004 4433.
Bristol Aquarium is home to thousands of aquatic creatures, with over 40 displays and 250 different species. The animals come from across the world, and the aquarium is committed to conservation, sustainability, and education. Regional Sales Manager, Will Coles, outlines how Aqua have been supporting the facility with their temperature control.
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