Rapid Chillers Delivers Energy-Efficient Cooling Upgrade for Plastics Manufacturer

A leading plastics manufacturer operating out of a 5,000 sq. ft facility partnered with Rapid Chillers to implement a high-efficiency cooling system that significantly lowered their energy costs and improved production performance. The manufacturer, known for producing both small and large production runs using single and multi-impression mould tools, required a modern, scalable cooling solution without the burden of upfront capital investment.

By leveraging Rapid Chillers’ SmartChill Subscription Plan, the company gained access to cutting-edge cooling technology with full-service support—installation, maintenance, and future-proof upgrades—all under a predictable monthly rate.

The Challenge

The manufacturer was relying on an outdated chiller that ran continuously at full capacity, regardless of seasonal temperature changes. This inefficiency led to excessive energy consumption and inflated operational costs—especially during winter months when natural cooling opportunities were being wasted.

Due to the substantial and consistent cooling demands of their moulding machinery, the company needed a smarter system—one that could dynamically adapt to ambient conditions and reduce their carbon footprint. Additionally, they preferred a rental-based solution to avoid large upfront equipment costs and long-term ownership responsibilities.

The Solution

Rapid Chillers proposed a modern Free Cooling System bundled within their SmartChill Subscription—a flexible hire model designed to deliver full temperature control solutions with zero capital expenditure.

The upgraded system included a 45kW Rapid i-Chill unit paired with a dry air cooler, designed to switch automatically between mechanical and free cooling based on external temperatures. During colder months, this setup dramatically reduces the system’s reliance on mechanical cooling, cutting energy usage by up to 80%.

Through a detailed site assessment, Rapid Chillers engineered the solution to meet the manufacturer’s unique production needs—balancing performance, reliability, and energy efficiency. The subscription plan also covers 24/7 emergency support, preventive maintenance, equipment replacements, and future upgrades.

The Result

Since the installation, the manufacturer has reported significant reductions in energy consumption and a more stable, cost-effective cooling process. The adaptive free cooling system not only optimises efficiency but also supports the company’s sustainability goals.

The all-inclusive monthly plan ensures no hidden costs, no unexpected downtime, and the flexibility to scale or upgrade as business needs evolve. In the event of a failure, Rapid Chillers’ contingency plan ensures fast access to replacement units, safeguarding production uptime.

With Rapid Chillers’ SmartChill solution, the manufacturer achieved peace of mind, improved operational efficiency, and long-term cost savings—without the risks or overhead of traditional ownership.