PROCESS COOLING

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STABLE PROCESSES FOR MAXIMUM EFFICIENCY

Stable production processes are key for you to stay ahead of the competition and continue being successful. With the perfect chiller solution, you can achieve maximum efficiency for your machines. Additionally, you will benefit from reduced operating costs by saving energy and water, and also support your continuous high production quality level.

A significant part of the energy and water savings is achieved through the optimal choice of chillers and setup of the cooling system with its parameters, saving up to 95% water and up to 60% energy compared to conventional evaporative cooling tower systems.

Whether you need a process cooling system for your injection molding machines, your cast or blown-film lines, or any other plastic converting process, we can offer the right concept to meet your specific requirements. It is a matter of choosing the right dimensioned system to be able to save as much energy as possible, whilst fulfilling the cooling water supply.

To develop the ideal concept for your factory, our first step is to analyze your existing production setup. Based on this information, we then develop a tailor-made solution that will improve your production by enhancing your productivity, reducing your operating costs, and ensuring the safety of your processes. Our concept provides flexibility for enhancements should you encounter the need for future adaptations.

PROCESS COOLING SOLUTIONS

Process cooling equipment

Adiabatic cooling system
Closed-loop system
Single & double zone temperature control units
Pressurized water temperature control units (up to 180°C)
Portable chillers

Air cooled chillers
Water cooled chillers
Modular chillers
Pumping stations

GET IN TOUCH

Mr. Kristian Rieck
Director, Packaging Material Solutions
Email: [email protected]

Your benefits

By implementing the right cooling system, you can take advantage of a stabilized production and reduced operating costs. This can be on any scale you wish – ranging from single temperature control units to air cooled chillers or even complete factory cooling solutions.

As specialists in the field, we can help to further optimize your plastic processing production with our tailor-made process cooling solutions. These are suitable for all plastic processing applications. Our smart and scalable concepts, high-quality machines, and local technical support are your guarantee of safety in production.

Stable production process
Continuous high-quality production
Environmentally friendly production
- Up to 60% energy reduction
- Up to 95% water reduction
- No added chemical
Reduced cycle time
- Cost reduction for cooling
- Reliable process
- Increased output
Clean cooling water
Scalable & upgradable systems

Case study

The situation

An Asian plastic converting company, which specializes in sheet extrusion and thermoform machines producing cups, lids and trays for coffee houses, and ready meals, were using open cooling towers to chill their running machines. This equipment requires an initially low investment, but also entails high operating costs owing to water evaporation, energy consumption and the usage of additional chemicals. As a result, the company was losing out on profits in view of the low throughput and rising energy costs.

The challenge

Because of the inefficient system installed, the company’s facility had not enough cooling capacity to run their extruders at maximum capacity, leading to an unstable process and a low throughput. In addition, the existing process required added chemicals. These are known to have a negative environmental impact and also increase operational costs.

To improve the profitability of the business, the aim was to design a closed loop system – one that would run smoothly without the need of additional chemicals and save energy.

The Rieckermann solution

Rieckermann had conducted a feasibility study for the company, which forecast that the installation of a new central process cooling system would provide the company with a quick return on investment (ROI). These results persuaded the company to go ahead with an investment in high-quality European equipment that would offer them potential annual savings of 50% as compared with their existing system.

Rieckermann’s central process cooling system, including air cooled chillers outside and temperature control units at individual machines, was easily linked in with the existing process without causing any lengthy disruption to daily production activities. The system did not require any additional space, and parts of the system could connect to the facility’s existing pipes. The installed system can also be extended should there be any plans for future expansion.

The key result

Although a higher investment was needed for Rieckermann’s solution (compared to a solution that uses water cooling towers), it offered a quick ROI period of around 2.25 years and boosts profits considering its 50% reduction of energy costs annually. Thus, the converting company could benefit from lower running costs for their installed base.

Thanks to more efficient cooling, which results in a higher throughput and a stable process, the company can now operate their machines at higher speed. They also do not need to spend money on the additional chemicals that were required by the old system and can save up to 98% of water using the closed loop system with an improved green footprint.