INDUSTRIAL COOLING


boilers and improve energy effi ciency. As part of its sustainability strategy, Organon is gradually installing Trane heat pumps across its facilities. The fi rst project, completed in May 2024, involved two water-to-water heat pumps (RTSF 070 G) in a manufacturing building. These units provide cooling for compressed air treatment and recover the heat, which is then distributed to the central heating network. This project saves 7,700 gigajoules of energy annually,


roughly equivalent to 243,000 cubic metres of gas. Organon plans further upgrades, including adapting air handling units for low-temperature heating, to reduce gas reliance and become climate neutral by 2035. These changes refl ect a signifi cant shift: from fuel-based heating to electrifi ed, balanced energy fl ows. Waste heat is not a nuisance; it’s a resource waiting to be tapped. Thermal management systems allow industries to rethink their relationship with heat, transforming what was once discarded into a valuable input. Heat pumps, though over a century old in concept, have evolved through advances in thermodynamic design, low-GWP refrigerants, and compressor and control technologies. Today, they off er a clean alternative to fossil-fuel heating for low- to medium- temperature processes. Heat pumps like the Trane RTSF HT can boost recovered


energy up to 110°C, meeting a wide range of process needs beyond space heating or domestic hot water. Fully electrifi ed thermal systems deliver both hot and chilled water, recovering and repurposing energy without generating on-site carbon or NOₓ emissions.


Simultaneous heating and cooling systems are three to four times more effi cient than traditional methods, positively impacting the bottom line. A modern heat pump can generate three to four kilowatts of useful energy from one kilowatt of input, achieving an average effi ciency ratio of 300–400%, more than triple that of a boiler. The benefi ts extend beyond performance. By combining heating and cooling systems, facilities reduce upfront investments, save space, and cut operating costs. This is the systems approach in action. Given the process-heavy nature of industrial operations, gaining control over temperature systems can quickly reduce energy use, emissions, and utility bills. While concerns around the industrial use of heat pumps persist, the benefi ts far outweigh the barriers. Common objections, about complexity, cost, or site limitations, often refl ect legacy thinking rooted in siloed systems. Upfront costs for integrated technologies can be higher, but these are off set by long-term savings. All-in-one thermal systems often achieve paybacks in just two to three years due to improved effi ciency and lower operating costs. Designing a net-zero facility requires coordination among architects, engineers, and contractors, but the core technologies already exist. The focus should be on converting existing plants to thermal systems and gaining market acceptance. Around 80% of current projects are retrofi ts, not new builds, proof that this model is viable for existing facilities. Moving from separate to integrated systems doesn’t mean


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reinventing the plant. It means rethinking how energy fl ows through it.


Case study: Saint Jean Saint Jean, a French pasta manufacturer, sought a temporary 150kW cooling solution to cover summer demand. What began as a standard project quickly evolved into a strategic rethink of the plant’s heating and cooling setup. During the site visit, Trane engineers, aware of Saint Jean’s


energy effi ciency goals, proposed heat pumps that would not only meet the cooling need but also replace the plant’s 300kW fossil-fuel boiler system. The installation of two Trane City RTSF heat pumps, integrated with existing chillers, allowed the facility to harness and boost waste heat from the cooling process. The result: a 68% reduction in heating costs and a major


drop in emissions. The system delivered 150kW of cooling and 300kW of heating, with cold water temperatures between -8°C and -4°C and hot water up to 60°C. This project exemplifi es how integrated systems can deliver both performance and sustainability. Redefi ning how heating and cooling systems are managed is vital for energy effi ciency and decarbonisation. Thermal management is no longer about choosing the right boiler or chiller; it’s a strategic approach to energy optimisation and operational resilience. As manufacturers across Europe seek ways to meet net-zero goals, the case for integrated thermal systems grows stronger. But the biggest shift is mental: moving from disconnected systems to a model where energy is continuous, recoverable, and independent. Reimagining heating and cooling as a single thermal system is not just a technological shift; it’s a leadership one. By replacing siloed thinking with systems thinking, industrial operators can reduce energy waste, cut emissions, and future- proof their operations. The mindset is already changing. Now it’s time to scale it.


"Thermal


management is no longer about


choosing the right boiler or chiller; it’s a strategic approach to energy optimisation and


operational resilience."


www.acr-news.com • October 2025 27


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