Company
Company
One of the UK’s innovative manufacturers in the personal care industry relies on the latest cooling technologies to manufacture many popular bath oils, gels, mouth washes, body lotions, fragrances, and niche brands.
Over one million units are produced each month. As well as filling tubes, jars and bottles, the company’s cello and shrink-wrapping assembly enables goods to leave the site ready for retail. The plant has two tube fillers handling 5ml – 300ml used for creams and shampoos and an adjacent high-speed filler for fragrances for multiples and niche brands.
Challenge
The company’s strong environmental policy had already seen investments that minimised dependency on mains water along with roof top photovoltaics to reduce energy requirements. Replacing the aged chillers to address environmental concerns and attain energy efficiencies and optimal performance levels was required.
All of the company’s products have their own formulation, requiring varying degrees of heating and cooling. Production could not be interrupted, critical cooling is required 24/7, all year round, if the company can’t cool, it can’t manufacture.
Solution
The business invested in an Aermec NRV modular chiller for the cream room where a number of mixing vessels are located. This addressed environmental concerns and the modular approach provided flexibility, enabling extra modules to be added at a later date as the cooling needs grew.
The switchover to the new chiller took place without the need for standby chillers. Hot filled products were re-scheduled so that production was not impacted during the installation. The work was completed before production was ramped up for the Christmas period.
Installation and commissioning including all the pipework, electrics and pump sets was scheduled over a seven-day period. The system is a closed system circuit using largely recycled water, providing cooling down to 5⁰C.
Result
Integrated free cooling offers further energy efficiencies and the simplified maintenance was also a bonus – the refrigerant components are located in a draw that slides out from the front. Noise concerns were alleviated as the chiller was designed to be quiet, guaranteeing acoustic comfort using the night mode profile. Aluminium micro-channel coils provide high levels of efficiency and less refrigerant is used compared to tradition cooper/aluminium coils.
With the personal care market set to continue growing, thanks to the adoption of a modular approach for cooling, additional modules can be added when the manufacturing capacity needs to be increased. This provides flexibility as the personal care business is constantly evolving.
NRV modular chiller for 24/7 critical coolingClosed circuit systemWater management -recycled water provides cooling down to 5ºCSwitched over planned without the use of standby chillersGuaranteed acoustic comfortMaintenance simplifiedModular approach facilitates future expansion plans
Being a significant player in the European air conditioning market for over 60 years, we are dedicated to the development and testing of our products and the value they bring to our customers. Not just at install, but the lifetime value of an Aermec installation. We believe in the importance of continual research and development, with particular emphasis on rigorous testing of every chiller and heat pump after its assembly, before it is dispatched.
Registered in England Company No. 3112873
