60kW Factory Cooling Rapid Deployment for Injection Moulding Operations
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The Challenge
A mid-sized injection moulding facility in the East Midlands required urgent 60kW factory cooling following a critical process chiller failure that threatened production shutdown.
Their primary process chiller, responsible for cooling 14 injection moulding machines operating 24/7, suffered a compressor failure overnight. The OEM lead time for a replacement compressor was 8–10 working days.
With coolant temperatures rising and cycle times moving out of tolerance, the site manager was facing a stark choice: halt production entirely, or find a working temporary chiller hire solution fast. Stopping the line wasn’t a realistic option — the facility was mid-run on a large automotive components order with fixed delivery deadlines.
The Survey
An engineer attended the site within 4 hours of the call to assess cooling demand and connection points.
Cooling demand required approximately 55–60kW of process cooling at a 12°C supply temperature. Flow rate was approximately 28 litres per minute, calculated from the system’s existing ΔT design parameters. The plant’s existing pipework termination points were in good condition, and suitable three-phase power was available within 15 metres of the proposed chiller position at the loading bay.
A key constraint was a noise limit of 72dB(A) during evening operation, which ruled out several standard hire units and required a low-noise solution.
The Solution
The unit was delivered and commissioned overnight. Our engineer completed pipework connections to the existing manifold, followed by a full system flush and pressure test.
Supply temperature stabilized at 11.8°C within 40 minutes of start-up — slightly tighter than the facility’s own system had been achieving. The 60kW capacity also provided useful headroom when additional moulding machines were brought back online the following morning ahead of schedule.
The Result
The facility ran without interruption for the 11 days it took to complete the permanent repair. The automotive components order was fulfilled on time, with zero rejected parts attributed to thermal process variation during the hire period. The site manager later confirmed that mould cycle consistency had actually improved slightly during the hire, which he attributed to the more stable coolant temperature the hire unit provided compared to their existing legacy chiller system.
- 11 days uninterrupted production with zero quality deviations or rejected parts
- On-time delivery of automotive components without production disruption
- Improved mould cycle stability compared to legacy cooling system
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