Enhancing Production and Uptime with Expert Water Treatment at IG Design Group

Keeping production running smoothly is vital for every manufacturer. Efficiency, reliability, and longevity are critical considerations in managing closed-circuit process cooling and chillers. When machines break down unexpectedly and water-related problems stop production, maintenance managers and operators know the hassle all too well. At IG Design Group UK’s Glamorgan site in Wales, when signs of corrosion, sludge build-up, and unplanned equipment stoppages started to appear, IG Design Group partnered with ICS Cool Energy to deliver a specialist water treatment solution.

The Challenge

IG Design Group’s plant is home to advanced vacuum metallisers and high-speed printing machinery. These systems operate under demanding conditions, making reliable cooling an absolute must. The machines in the vacuum chamber operate at extreme temperatures, evaporating aluminium at 1500 °C then chilling the foil to –15 °C, placing immense thermal stress on internal components. Meanwhile, printing-press chillers must maintain water at 18–22 °C to preserve ink viscosity, drum concentricity and paper-drying performance.

Like many manufacturers, IG Design Group began to notice that their systems were showing signs of strain. Corrosion began to affect internal components of their machines made from a mix of steel, brass, copper, and aluminium, driven by uncontrolled water pH. At times, the water in the printing circuits appeared thick and sludgy, which the operators likened to “chocolate milk.” Such conditions would trigger sensors, halt presses, and force the team into frequent cleanups, interrupting production flow and increasing operational headaches.

While routine maintenance was in place, previous support from a local provider had not always met evolving water-treatment standards or responded quickly enough to emerging issues. Recognising the need for a more specialised, responsive service, IG Design Group’s leadership reached out to ICS Cool Energy to ensure a comprehensive approach backed by water treatment expertise.

Plant Engineer David Allen described the urgency of the situation: “Before the ICS Cool Energy site survey and intervention, we were facing corrosion inside the metalliser and sludge-related shutdowns every few hours.”

The Solution

The project began with a site survey and data gathering. This was immediately followed by on-site water sampling and laboratory analysis by the ICS Cool Energy in-house water treatment specialist to understand the specific causes of water-quality issues and establish clear treatment targets.

Working collaboratively with IG Design Group’s team, ICS Cool Energy’s service engineers made targeted adjustments, including fine-tuning the chill-water set point in the metalliser’s chiller to stabilise operating temperatures and benefit overall press performance. They performed a comprehensive purge of the coolant in the metalliser circuit, removing scale and corrosive residues that threatened long-term reliability, and cleaned the printing-press drums and heat exchangers to restore efficient heat transfer.

To address ongoing chemical imbalances, ICS Cool Energy developed a bespoke dosing programme to rebalance water chemistry and arrest further corrosion. The solution was reinforced by proactive maintenance, with quarterly site visits arranged for water sampling, chemical replenishment, and inspection of pumps, filters, and sensors. To further safeguard operations, a phased upgrade to side-stream filtration was proposed, helping to capture fine particulates before they could accumulate as sludge and cause further trouble.

Victor Capewell, Technical Sales Engineer at ICS Cool Energy, explains the approach: “The intervention restored reliable operation, improved heat-transfer efficiency and extended equipment life. By scheduling quarterly visits, controlling water chemistry and recommending cost-effective filtration, we’ve provided IG Design UK with a sustainable maintenance framework to future proof their operations.”

The Result

The results of ICS Cool Energy’s intervention were felt almost immediately. Production stoppages linked to water quality became a thing of the past; press availability surged, and operators no longer had to contend with “chocolate milk” coolant or sensors tripped by sludge. The improved temperature control eliminated dangerous steam incidents, helping to ensure a safe and reliable work environment.

Financially, a fixed-cost annual service contract gave IG Design Group much-needed predictability for maintenance budgets. The partnership with ICS Cool Energy established a new standard of responsiveness and support, one that empowered the onsite team to focus on production rather than firefighting unexpected breakdowns.

“Water treatment is not simply an operational expense but an essential investment in the cooling system’s performance and reliability. Adopting a comprehensive water management strategy mitigates risks, reduces maintenance costs, and safeguards long-term operational efficiency,” said Victor Capewell.

Looking to the future, IG Design Group is moving ahead with the installation of side-stream filtration across its circuits. Monthly monitoring of water-treatment chemical levels will continue to support corrosion control, and an expanded service contract will bring consistent expertise to all auxiliary chillers.

As David Allen remarked: “We count on the support and early warning of any deviations that can safeguard our continuous production.”

Testimonials

Plant Engineer David Allen:

“Before the ICS Cool Energy site survey and intervention, we were facing corrosion inside the metalliser and sludge-related shutdowns every few hours.”

“We count on the support and early warning of any deviations that can safeguard our continuous production.”

Victor Capewell, Technical Sales Engineer at ICS Cool Energy:

“The intervention restored reliable operation, improved heat-transfer efficiency and extended equipment life. By scheduling quarterly visits, controlling water chemistry and recommending cost-effective filtration, we’ve provided IG Design UK with a sustainable maintenance framework to future proof their operations.”

“Water treatment is not simply an operational expense but an essential investment in the cooling system’s performance and reliability. Adopting a comprehensive water management strategy mitigates risks, reduces maintenance costs, and safeguards long-term operational efficiency,

For more information on how to protect you production from downtime, visit our water treatment page here