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A leading supplier in the construction industry was facing downtime on a crucial piece of machining equipment due to a failed oil cooling system. The machine tool’s built-in coil-in-tank oil chiller had broken beyond economic repair, threatening production schedules. The client, a service contract holder with Refcool, needed an immediate and effective replacement that met modern standards. Refcool stepped in to design and install a custom single-phase machine tool oil chiller solution. This involved sourcing a compact chiller unit and configuring it to circulate the machine’s cutting oil externally, all within the limited space available on the factory floor.
The primary challenge was that an exact like-for-like replacement of the old oil cooler did not exist – at least not one that complied with current EU regulations and the client’s single-phase power availability. The original system was an internal coil submerged in the machine’s oil tank, which, while simple, was outdated. We needed to devise a new method to keep the oil at around 20 °C consistently. Key challenges included:
Space Constraints: The machine area had very little free space to add new equipment. The solution had to be very compact and possibly split into components (like a separate chiller and pump) to fit the tight quarters.
Power Supply: The facility could only support a single-phase power supply for this auxiliary system, which limited the size of the chiller unit we could use. We needed a high-performance 230V chiller that could provide sufficient cooling (approximately 2–3 kW of cooling capacity) within those electrical constraints.
Integration with Existing Tank: Since the old coil was inside the oil tank, the new system had to interface with that tank to draw oil out, cool it, and return it. This meant fabricating a plate or adapter for the tank opening once the coil was removed, and ensuring oil flow would be smooth and leak-free.
Oil Compatibility and Reliability: Pumping oil (especially if it’s a light hydraulic or cutting oil) requires careful selection of pump and hose materials for compatibility. The pump must be robust enough for continuous operation, and the hoses must handle oil without degrading. Longevity was a concern as the client wanted a solution that would last years with routine maintenance.
Minimal Downtime: The machine tool was critical to production, so the installation had to be swift. The client wanted the machine back in operation quickly, meaning Refcool had to prefabricate as much as possible and then execute a quick retrofit.
Refcool’s engineers devised a two-part solution: a 2.5 kW single-phase chiller unit paired with a remote pump and circulation loop. After calculations, a 2.5 kW cooling capacity was determined to be sufficient to maintain the oil at the target 20 °C. We collaborated with a reputable European chiller manufacturer to source a compact, air-cooled chiller that runs on single-phase power and could be customized for oil cooling duty (including appropriate temperature controls and safeties for oil applications).
For the circulation, we installed an external pumping system. We fabricated a steel cover plate for the existing oil tank – this plate sealed the top of the tank where the old coil had been accessed, and it also provided ports for oil outlet and return. Through this, oil is drawn out of the tank, passed through the new chiller’s oil-to-refrigerant heat exchanger, and then fed back into the tank continuously. The pump selected was a single-phase gear pump with enough flow to ensure proper heat removal, and it was mounted on a small base plate on the floor near the machine. This floor-mounted pump assembly was connected to the tank plate via custom hydraulic oil hoses designed for durability and oil compatibility. We chose high-quality, reinforced hoses to handle the oil temperature and any pressure from the pump without issue. These hoses also reduce vibration transmission and make the maintenance easier (they can be disconnected with valves if needed).
The chiller unit itself was installed adjacent to the machine, occupying a footprint akin to a small cabinet. It included its own oil heat exchanger and coolant circuit. We set the chiller’s thermostat to maintain the oil at approximately 20 °C, with a slight hysteresis to avoid short cycling.
During installation, our team quickly decommissioned the old coil system, mounted the new tank cover with proper gaskets, and hooked up the pump and chiller loop. We flushed the system to ensure no debris from fabrication remained in the oil lines. Then we filled the oil loop and powered up the chiller. Within a short commissioning period, the oil temperature came down to the desired range and stabilized.
An additional aspect of our service was disposing of the old equipment. We safely removed the old coil and any related components and ensured they were disposed of or recycled properly, which the client appreciated as it relieved them of that burden.
The machine tool was brought back to life with a modern oil cooling system that has markedly improved its performance and reliability. Thanks to the new chiller, the cutting oil now consistently stays at ~20 °C even during heavy machining operations, as required. This stable oil temperature has multiple benefits: it prevents thermal expansion issues in machine components (improving machining precision), it extends the oil’s usable life, and it keeps the machine’s internal parts (spindle, hydraulics, etc.) properly cooled and lubricated.
The client observed that the machine can run for longer periods without hitting thermal alarms or requiring cool-down pauses, directly boosting productivity. The solution’s compact nature meant it integrated into their workshop seamlessly – operators have commented that the chiller unit takes up minimal space and operates quietly in the background. Maintenance staff are pleased with the accessibility: the pump and chiller can be serviced without dismantling the machine, and the use of common single-phase power means no special electrical accommodations were needed.
Refcool also set up an ongoing service plan for this unit as part of our contract with the client. This means the oil chiller will be regularly serviced along with other chillers on site, ensuring it remains in peak condition. The client has peace of mind knowing that Refcool will support the equipment with preventative maintenance, reducing the chance of future failures. The old, inefficient coil system is gone, replaced by a clean, energy-efficient chiller that likely uses far less electricity (modern refrigeration cycle vs. old resistive or inefficient cooling).
In conclusion, this case demonstrates Refcool’s agility in solving a client’s urgent cooling problem with a custom, cost-effective retrofit solution. A critical machine tool was saved from obsolescence, and the client avoided prolonged downtime and the much larger expense of replacing the entire machine. It’s a persuasive example for any manufacturer facing a similar challenge: Refcool can engineer a tailored upgrade to aging cooling systems that improves performance and meets modern standards.
