2000kW Chiller Package for Pharmaceutical Production Failure
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The Challenge
A pharmaceutical manufacturer faced an immediate production risk after their primary process chiller failed mid-cycle. The facility runs a continuous API (active pharmaceutical ingredient) synthesis process that requires stable coolant temperatures between 8°C and 12°C. Any deviation beyond ±1°C risks batch integrity and regulatory compliance under their GMP framework.
With continuous production in place, any prolonged downtime risked significant batch losses and costly disruption to supply commitments.
Their in-house engineering team had already identified the fault — a compressor failure on their 185kW fixed installation — but lead times for a replacement compressor were running at 4 to 6 weeks. They needed cooling capacity back online within days, not weeks.
The Survey
We sent an engineer to the site within 24 hours of the initial call. The main constraints were immediately clear: the plant room had no external footprint for a large generator or a conventional hire unit; the facility operated on a closed glycol loop at 30% concentration; and all hired equipment needed to be compatible with their existing pipework connections (DN100 flanged).
The process also demanded low-noise operation — the site sat within 50 metres of laboratory spaces with active stability studies running, meaning acoustic limits applied under their site operating procedures.
The Solution
We specified a 2000kW chiller package from our hire fleet — a self-contained air-cooled unit with an integrated pump set and buffer vessel, configured for glycol-compatible operation. The unit was preconfigured off-site to the required flow conditions, reducing commissioning time.
Given the DN100 flange requirement, we fabricated bespoke connecting hoses in advance. The unit was positioned in an adjacent service yard, with a temporary insulated pipework run of approximately 18 metres connecting into their existing circuit via pre-installed isolation valves.
From initial survey to full operation, the system was live within just 71 hours.
The Result
Full production was restored within four days following the original failure, ensuring the site remained within its critical operating window.
Key outcomes of the project included:
– Full GMP-compliant production restored within 4 days with zero batch loss or quality deviation
– Coolant temperatures maintained at 10°C ±0.5°C
– Continuous operation over a 7-week hire period
– Seamless integration with existing process systems
The engineering manager also noted that the pre-configured setup and same-day delivery from survey to decision significantly reduced the documentation burden for their quality team, with the hire unit operating within the same parameters as the existing system.
Need rapid-response cooling for critical pharmaceutical or process environments? Rapid Chillers delivers 2000kW chiller package systems for critical pharmaceutical and GMP environments within days — not weeks.
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