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Refcool delivered a full cooling system for a new plastics injection molding facility – designing a twin-circuit pipework network, integrating new chillers and dry coolers with existing equipment, and commissioning the system on a tight timeline.
When a large international manufacturer relocated its plastic injection molding operations to a brand-new facility, it needed a complete turnkey cooling solution to support around 30 molding machines. The company sought out competitive bids for supplying cooling equipment and installing a comprehensive distribution network in the new plant. Refcool won the tender based on its design proposal and track record, taking on responsibility to equip the facility with a twin-circuit chilled water system that could handle the varied cooling needs of numerous injection molding machines.
The project involved setting up a cooling infrastructure essentially from scratch, under a tight deadline aligned with the plant’s launch. Key challenges included:
Comprehensive Coverage: The system had to serve ~30 injection molding machines of different sizes and cooling requirements scattered throughout the facility. This meant designing a distribution network with sufficient capacity and balanced flow to each machine.
Twin-Circuit Design: The client’s process required two separate cooling circuits. Typically, in injection molding, one circuit might supply colder water for the molds and another slightly warmer circuit for hydraulic oil or machine cooling. Implementing a dual-loop system in one plant adds complexity – two sets of mains and branch lines, and possibly different cooling equipment for each loop.
Integration of Old and New Equipment: The client planned to reuse some existing cooling equipment from their former site and supplement it with new units. Specifically, some chillers or accessories were relocated, and Refcool was to provide a new high-efficiency dry air blast cooler for one circuit and a new packaged chiller for the other. Ensuring the old and new components worked together seamlessly was a critical part of the challenge.
Large Piping Network: The distribution system had to include large-diameter mains (approximately 3″ pipes) with multiple 2″ branch lines tapping off to individual machines. Laying out this network to be efficient and leak-free, while navigating the facility’s layout, required careful planning. Thermal expansion, support, and insulation of the extensive piping were also concerns.
Tight Timeframe: The relocation timeline meant Refcool had a fixed window to get the cooling system up and running. Any delays could postpone the start of production in the new facility, which was not an option for the client.
Refcool’s engineering team designed a dual-circuit cooling network tailor-made for the new plant. After surveying the machine layout, we installed two sets of main lines in ABS thermoplastic pipe: one for the chilled water circuit and one for the cooling water/oil circuit. Each main was 3″ in diameter to carry the high flow volume needed. From these mains, we ran a series of 2″ branch lines, routing to clusters of molding machines. In total, around 30 drop points were created, each with shut-off and balancing valves so that flow to each machine could be regulated according to its demand. The use of ABS piping offered corrosion-free performance and smoother installation compared to traditional metal pipes, and we solvent-welded the joints to ensure reliability under continuous service.
On the equipment side, Refcool supplied two major new components:
A high-efficiency dry air blast cooler for the hydraulic/oil cooling circuit. This air blast cooler rejects heat to the atmosphere without consuming water (ideal for the slightly higher temperature loop). It was selected for its energy-saving design and ability to maintain cooling performance even in summer, using ambient air and fans to dissipate heat.
A new packaged chiller for the other circuit (likely the colder water for molds). This chiller was sized to handle the peak cooling load of all connected machines on that loop, and came with modern controls and a high EER (energy efficiency ratio) to minimize electrical consumption.
We integrated the existing equipment relocated from the old site into the new setup. For example, if the client kept an existing chiller or pumps, we incorporated those into the respective circuit and ensured compatibility. New pump sets were provided where needed to circulate water through the large pipe network; these pumps were chosen for reliability and were installed with duty/standby configuration to add resilience.
Refcool’s experienced installation crew undertook the complete mechanical and electrical installation. We mounted and connected the air blast cooler on the exterior of the building, with insulated piping running to it. The interior pipework was installed neatly overhead, with clear labeling of the two circuits for ease of maintenance. All branch lines were leak-tested and insulated or heat-traced as appropriate (some injection molding applications prefer certain water temperatures, so maintaining those temps along the distribution was important).
Finally, we commissioned the system by firing up the new chiller and cooler, circulating water through the network, and methodically balancing flows to each machine. We also trained the facility’s maintenance staff on operating the new system and how to switch between the two circuits or adjust flow if machine configurations change.
Refcool successfully delivered a turnkey cooling system that was fully operational within the required timeframe, syncing perfectly with the opening of the new injection molding facility. As production commenced, the client immediately benefited from the efficient and robust cooling infrastructure:
Each of the ~30 machines receives adequate cooling, which has kept cycle times optimal and prevented any overheating issues in molds or hydraulic systems.
The twin-circuit design allows the facility to run different temperature loops optimally – e.g., colder water for mold cooling and a warmer loop for other parts – improving overall process efficiency and part quality.
The new dry air blast cooler and packaged chiller are delivering energy-efficient performance. The dry cooler in particular has reduced water usage and maintenance compared to an evaporative system, aligning with the company’s environmental goals. Meanwhile, the advanced chiller operates with much lower power draw than older models, saving on energy costs.
Integration of the legacy equipment was seamless; by combining it with new technology, the client maximized their investment and faced no compatibility problems. The whole system functions as a cohesive unit.
Importantly, the project was delivered on a tight schedule and within budget. Commissioning tests showed the system achieving the desired flow rates and temperatures at all use points, and the client was able to ramp up production as planned with zero delays due to cooling.
This case stands as a persuasive example of Refcool’s capability in full-scope industrial installations. We took a greenfield site and turned it into a fully cooled manufacturing environment in a short span of time. The client’s satisfaction – evidenced by smooth operations and meeting all performance targets – underscores our expertise in designing and executing turnkey cooling solutions for complex industrial facilities.