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A cutting-edge life sciences facility required a high-end cooling solution for a mission-critical process. The client, known for executing complex projects in the pharma/biotech sector, needed a custom-engineered system that could provide ultra-reliable cooling with strict temperature stability. Refcool was selected to design and manufacture a bespoke critical cooling skid to meet these demands, leveraging our experience in tailored cooling systems for sensitive applications.
The project presented unique challenges in both design and logistics. First, the cooling system had to deliver a very stable low-temperature fluid (propylene glycol below 0 °C) to the process, with absolutely no interruptions. This meant incorporating redundancy and fail-safes to guarantee uptime for the life sciences application, where any temperature deviation could affect research or production quality. Second, space constraints and site accessibility were a major concern. The equipment would be installed deep inside the facility through a tight access route, requiring the skid to be modular or split for transport. Additionally, the client demanded the highest standards of construction and finish – the system needed not only to perform flawlessly but also to reflect quality in its build, fitting for a high-tech laboratory environment.
Refcool’s engineering team developed a twin-chiller cooling skid mounted on a split-frame design. The skid was essentially divided into sections that could be easily disassembled after factory testing, allowing each part to navigate the narrow entry to the installation site. On this skid, two identical chillers were installed in a duty/standby configuration: one chiller runs while the other is on backup, ready to take over instantly if needed. The chillers circulate propylene glycol coolant at sub-zero temperatures through a large, insulated weir (buffer) tank, ensuring a substantial thermal reserve for the process. On the process side, dual high-quality pumps (also in duty/standby setup) deliver a fixed flow of chilled glycol to the facility, maintaining extremely stable temperatures critical for the client’s life science processes.
To meet the client’s control requirements, Refcool collaborated closely with the client’s team who provided the interface controls, while Refcool focused on the full mechanical design and build. This partnership ensured seamless integration of the skid into the broader system controls. The entire assembly was modeled in 3D CAD prior to fabrication, optimizing the layout for ease of maintenance – all key valves and components are readily accessible. The piping was executed in welded stainless steel for purity and durability, and the skid frame along with tanks and chillers were finished in a color-coordinated scheme. The result is an impressive, “high-end” cooling skid that not only meets the technical specs but also stands out visually as a showcase of engineering quality.
Delivered on a tight schedule, the custom cooling skid fully met the high standards of the life sciences client. Upon installation, the system immediately provided the reliable, precise cooling needed – temperature stability in the process was excellent, and the large buffer tank plus smart controls eliminated any risk of thermal fluctuations. Thanks to the dual chillers and pumps, the facility now has built-in redundancy; maintenance or an unexpected issue on one unit will not interrupt operations, a critical factor for continuous life science processes. The modular skid design greatly simplified installation in the confined site, validating the upfront planning and 3D design work Refcool invested. The client was impressed with the excellence in design and finish – from the polished stainless steel pipework to the thoughtfully laid-out components, the skid exemplifies quality craftsmanship. This project has become a standout reference for Refcool, demonstrating our capability to deliver bespoke critical cooling solutions that combine reliability, innovation, and superior build quality. It serves as a persuasive example to other prospective B2B customers in high-tech industries of how Refcool can meet and exceed challenging cooling requirements.
