200kW Factory Cooling Solution Restores Production After Critical Chiller Failure
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When a heavy machinery manufacturer in the West Midlands lost its primary industrial cooling system during a heatwave, production came to a halt. Stable factory floor temperatures are essential to maintain tolerances and protect operator safety.
We delivered a 200kW factory cooling solution within 48 hours, restoring operations and saving over £15,000 annually in energy costs.
The Challenge
A tier-one automotive parts supplier operating a 50,000 sq ft facility faced immediate disruption when its ageing ~180kW cooling system failed during 33°C conditions.
As temperatures rose to 29°C within four hours, CNC machines triggered thermal alarms, operators struggled in high heat, and production was forced to stop. Downtime was costing £8,500 per hour.
The Survey
An applications engineer attended the site within three hours to assess requirements and calculate the thermal load.
Key findings:
- Total load: 196kW steady state, peaking at 215kW
- Heat gains from CNC machining, welding processes, heat treatment, lighting, personnel (45 staff), and solar load
- Existing pipework and flow rate are suitable for a 200kW capacity
- 400A three-phase power is available
- External space available for chiller placement
- Noise considerations due to the nearby residential area
The Solution
We deployed a 200kW chiller integrated into the site’s existing chilled water system, supplying multiple air handling units across the factory floor.
Key features of the solution included:
Screw compressor technology. A twin-screw compressor was selected for durability and stable operation under continuous load, with slide valve unloading from 25% to 100% capacity.
High ambient capability. Their concrete pad faces west and gets full afternoon sun. We oversized the condenser coils and added variable speed fans rated for 35°C+ ambient temperatures. No high-pressure trips during heatwaves.
Sound attenuation. We supplied the chiller with acoustic compressor enclosures and low-speed condenser fans. Noise levels at 10 metres: 72 decibels. No complaints from neighbours.
Remote monitoring and control. The chiller has a touchscreen controller with Modbus TCP connectivity. We tied it into their existing BMS so the facilities team can monitor chiller status, adjust setpoints and receive alarms from the control room or their phones.
Glycol compatibility. Their system runs a 30% glycol mix for freeze protection. We programmed the chiller’s low-temperature cut-out and adjusted the evaporator flow parameters to match.
Future-proofed. The system was configured with sufficient headroom to accommodate an additional ~50kW of future load.
Installation was completed over a planned maintenance weekend. Our team completed mechanical and electrical connections, pressure testing, system charging, and full commissioning within the agreed window. By Monday morning, process water was flowing at the correct supply temperature of 8°C — right on spec for the client’s portioning and sealing lines.
The Result
The chiller was delivered within 48 hours, craned into position on a Saturday and commissioned by Sunday evening. Conditioned air was evenly distributed across the factory floor via existing air handling units, eliminating hot spots and restoring stable ambient conditions. Temperature stability was maintained within tight tolerances across all production areas.
Zero production loss beyond the initial shutdown. They met their weekly delivery targets. Delivery schedules were maintained without disruption to the end customer.
Energy costs reduced by 22% compared to the previous fixed-speed system. Their old system ran fixed-speed compressors that were either 100% on or off. Our variable speed fans and screw compressor with slide valve unloading match the cooling output to the actual demand. First-year energy savings: approximately £15,600.
Uptime has been 100%. The chiller has run 24/6 (they shut down Sundays for maintenance) for 14 months. No unplanned stops. The only intervention has been scheduled filter cleaning and quarterly oil sampling.
They’ve added capacity. The facility installed two new CNC machines six months ago, and the system absorbed the additional 30kW load without performance issues.
Maintenance costs are down. Their old system required emergency call-outs every few months. This one runs so reliably that the maintenance budget has been cut by 60%.
I used to lie awake worrying about that old chiller. Now I don't even think about it. That's peace of mind you can't put a price on
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