INDUSTRIAL SPOTLIGHT


ICS Cool Energy transforms manufacturing effi ciency at


machining centres For 25 years, two machining centre plants located in the West Midlands, have been dedicated to precision engineering and playing a key role in supplying components to leading truck and bus builders across the UK and Europe.


The overall outcome not only anticipates surpassing expectations but also positions


the customer for long-term success in their pursuit of operational excellence and


sustainability. I


n 2022, their operational effi ciency faced a critical challenge due to unreliable cooling systems, threatening production continuity and escalating maintenance costs. In response,


ICS Cool Energy stepped in with a bespoke solution redesigning their cooling infrastructure and setting the stage for production reliability, enhanced sustainability and savings forecasted at approximately 1.7 million Kw/hours for the two sites. The customer operates two plants with over 30 machining


centres in one location, and more than 60 at the second one, each dedicated to carrying fi nal machining operations on unique components to be supplied to major truck and bus builders. With the machines operating 24/7, maintaining uninterrupted cooling of the cutting fl uid has been paramount. The existing cooling setup, with onboard chillers fi tted on the machining centres in the harsh factory environment, proved vulnerable to breakdowns. These breakdowns not only resulted in costly maintenance


expenses but also threatened production schedules, leading to backlogs of components awaiting completion. The fact that the chillers had to work against higher ambient temperatures inside the plant, also contributed to less overall effi ciency. The customer sought a solution for improvement that would not only ensure reliable and uninterrupted production but also increase energy effi ciency, reduce maintenance costs, and align with their sustainability goals. To address these challenges, ICS Cool Energy proposed


a comprehensive solution. A detailed energy analysis was conducted to size the cooling requirements and quantify the potential benefi ts of the proposed solution. This provided the customer with valuable insights into expected energy savings and decarbonisation benefi ts. Recognising the need for a more robust and reliable cooling system, ICS Cool Energy recommended the installation of a central plant with optimally sized 450kW and 690kW run/ standby chillers and pumps located externally. This setup would supply cooling to the machining centres via a ring main, ensuring uninterrupted production even in the event of individual chiller failures. For additional effi ciency and


28 April 2024 • www.acr-news.com


sustainability gains, ICS Cool Energy suggested integrating Free Cooling technology that allows to capitalise on natural ambient temperatures to reduce mechanical energy consumption. The proposed solution not only addressed the immediate


production challenges but also aligned with the customer’s sustainability goals, with forecasted reductions in kW/hours usage and decarbonization benefi ts. Additionally, ICS Cool Energy guaranteed seamless installation around the customer’s continued production schedules, reaffi rming their commitment to minimizing disruption and maintaining operational continuity. The quality of the energy analysis demonstrating potential


benefi ts also allowed the customer to obtain a grant to fi nance part of the fi nal costs. Following the successful redesign, installation and commissioning of the new cooling system, the customer yielded immediate gains in operational effi ciency and improvements in production reliability, with fewer machine stoppages. In the fi rst plant with 450kW of cooling capacity, ICS Cool


Energy calculations estimated annual energy savings of £150,000, based on the original electricity cost quotation. Following the successful installation and commissioning, the second plant with 690kW of cooling capacity was projected to achieve even greater savings, with an estimated annual reduction of £305,000 in electricity costs. These signifi cant estimated savings can be achieved by a


remarkable decrease in projected kW/hours usage, with an estimated 500,000 kW/hours saved at the fi rst plant and an impressive 1.2 million kW/hours at plant two. The overall outcome not only anticipates surpassing


expectations but also positions the customer for long- term success in their pursuit of operational excellence and sustainability.


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