Life Science Manufacturer & Medical Moulder Partner With ICS Cool Energy

The Challenge

An industry leading global life science manufacturer and high-end medical moulder was looking to improve the energy efficiency of the chiller plant across their facilities. Their chillers are needed to provide precise and consistent process temperatures to maintain product quality and lower wastage.

The Solution

Following a site visit to carry out a survey and understand the manufacturer’s specific applications, facilities and temperature needs, ICS Cool Energy received their official RFQ.

To meet their unique requirements, the team specified:

384kW Aptus Free Cooling Chiller

This chiller unit operates with ozone friendly R410a refrigerant and boasts an exclusive dedicated coil, hermetic scroll compressor and is resistant to external wear. In summer, when external air temperatures are higher, this chiller unit will work as a normal chiller would, with the compressors running.

In mid-season, the unit will offer partial free cooling – reducing the operation of the compressor and energy required to run. Most importantly, in cooler ambient temperatures, thanks to the Free Cooling coil, the compressor will not be required to run – providing 100% Free Cooling.

1.1mW Imperium Air Cooled Chiller

This externally sited 14 off die-cast aluminium axial fan unit with semi-hermetic screw compressor was required for use on a separate building and offered the customer reduced life-cycle costs and allowed ease of communication through included Modbus interface.

Magnus Air Cooled Turbocor Chiller

This high efficiency & extra low noise chiller, running on R134a refrigerant, was selected as it offered an impressive operational saving of £55K a year over the inverter screw option and a payback period of 15 months.

Full Turnkey Solution & Ongoing Support

We provided a complete temperature control solution, so the manufacturer benefitted from a holistic approach and continuous support from one point of contact.

• Comprehensive site survey, existing equipment energy analysis, application and temperature consultation
• System design and specification
• On-site project management, equipment delivery, installation and commissioning
• System integration for optimum communication and management
• Extended warranties on chiller plant
• Planned Preventative Maintenance program
• 24/7 technical support and equipment contingency plan backed-up by our hire equipment division

European Cooling Plant Improvements

Having successfully completed these projects in the UK, ICS Cool Energy were asked to support a new cooling project to reduce energy consumption at another one of the customers facilities in Europe, whereby two externally sited air-cooled chillers were needed to provide cooling to a process line.

Our solution was to deliver, install and commission 2 x 900kW high-efficiency Imperium inverter screw chillers using the low GWP R513a refrigerant. The reliability of the inverter screw, superior part load performance, low GWP of the refrigerant, low refrigerant charge flooded evaporator and inclusion of electronic expansion valves (which alone save around 9% energy) offer significant energy savings.

The Result

The completion of these recent projects has meant the life science manufacturer has significantly reduced their energy consumption and increased their sustainability through the cooling plant upgrades –  5 chillers complete with pipework at 2 production sites, across 2 countries – saving them 10’s of thousands of pounds annually.