Repeat chiller delivery for a plastics manufacturing plant
Plastic production in Lithuania today is a powerful and energy-intensive industry, where the stability of cooling directly affects the quality of the final product. On a single extrusion circuit with a feed rate of 160 kg/h and a melt temperature of 220 °C, a tolerance of ±1.5 °C decides whether the product is suitable for use or for recycling.
Ūkė, UAB, registered in 2020, has gone from a local supplier to a sustainable industrial player in four years with a turnover of €4,146,621 and net profit of €1,427,391 based on 2023 data. The average annual revenue growth is about 35 % and production profitability exceeds 34 %, which is unattainable without energy control and temperature stability.
The main processes are extrusion and thermoforming, where the water temperature in the cooling circuit is kept at 12 °C → 18 °C, with a flow rate of up to 38 m³/h.A feed deviation of 2 °C increases the number of product defects by up to 10-12 %, which in monetary terms amounts to losses of up to 2000 € per shift.
To minimise this risk, the company has a two-circuit cooling system with a total heat load of ≈ 480 kW, one of whose circuits was previously serviced by a single unit with a capacity of ≈ 250 kW purchased through a service company.
Such a scheme is common throughout Europe: in about 70 % of cases, manufacturing companies turn to intermediaries who combine supply, installation and maintenance of equipment. However, with the accumulation of engineering expertise, the intermediary model loses its effectiveness.
The technological staff of Ūkė, UAB conducted an internal audit: the average cost of maintenance services was 7.5 % of the annual operating costs, and the time to coordinate repairs reached 10-14 days. These indicators had a direct impact on the productivity and energy economy of the company.
By 2024, the company entered the scaling phase – the launch of two additional extrusion lines with a capacity of 120 kW each and the modernisation of the thermoforming unit increased the load on the cooling circuit to 480-500 kW. Approximately 240-250 kW of cooling had to be added to compensate for peak loads. The technical parameters set are:
– Energy efficiency of at least EER = 3.1;
– Water flow rate 40 m³/k at 260 kPa head;
– Operating temperature range 12/7 → 35 °C;
– Noise level max. 65 dBA;
– Integration period max. 20 days.
When analysing the market, three service integrators offered solutions based on new units with prices starting from 54,000 € and delivery times of up to 45 days. The direct offer from EVROPROM proved to be optimal: the Climaveneta NX SL K 0914T 241 kW chiller with two independent R410A refrigerant circuits, four Danfoss SH300 and SH240 scroll compressors, an aluminium microchannel condenser and an integrated Lowara FCTE 65 pump is available from stock.
The decision to purchase the unit directly reduced the project costs by 8-12 %, equivalent to ≈ 5000-6000 € savings, and shortened the delivery time from 5 weeks to 17 days. In addition, the company received a complete package of technical documentation – passport, test reports and, moreover, a 12-month operating warranty. After the installation of the additional equipment, the total capacity of the cooling system increased to 482 kW and the temperature stability of the water in the circuit improved to ±0.3 °C.
Line capacity increased by 9.8 per cent, while electricity consumption increased by only 3.5 per cent, raising the integral energy efficiency ratio of the entire site from EER 2.9 to 3.2. This step was an indicator of the maturity of the engineering culture for Ūkė, UAB. Direct work with EVROPROM eliminated bureaucratic delays, reduced the cost of refrigeration to 0.31 kW/h/kW/refrigeration and ensured full control over the equipment cycle – from selection to operation.
Equipment and features of HVAC-integration of the enterprise
At the production site of Ūkė, UAB a Climaveneta chiller with a nominal cooling capacity of 241 kW, operating on R410A refrigerant, is installed. The model is equipped with two independent refrigeration circuits, which provides redundancy at partial loads and allows to maintain cooling stability when one compressor is out of cycle. Each circuit is controlled by a separate electronic expansion valve, and the capacity is regulated by a step algorithm 0-50-100 %, which reduces pressure drops and energy consumption. The unit utilises a Lowara hydromodule, an industrial-grade pump group with a head up to 280 kPa, an operating flow rate of 41 m³/h and a flow rate adapted to the heat load of the extrusion lines. The configuration eliminates the need for a separate pumping station, reducing heat losses.
The cooling circuit is water-to-water with a 500 l intermediate accumulator, which compensates for short-term temperature peaks at the time of pressing and stabilises the return flow at 18 °C ±0.3 °C.
The average feed temperature is maintained at 12 °C, which is optimal for moulding polymer products up to 5 mm thick.
The compressor section consists of two scroll units with a rated power of 2 × 47 kW, designed for operation at ambient temperatures up to 46 °C. The system has an energy efficiency ratio (EER) of 3.27 and a COP of 4.1 at partial loads, providing energy savings of up to 14 % compared to the previous generation. The condensers are aluminium-copper heat exchangers of microchannel type with high heat transfer and low aerodynamic resistance.
To reduce the noise level, axial fans Ø800 mm with frequency control are installed – the sound pressure level at a distance of 10 m does not exceed 63 dBa, which is important when the unit is located near production halls. The control system is implemented on the controller Climaveneta W3000TE, supporting Modbus RTU and BACnet, which simplifies integration into the existing automation of the enterprise. Key parameters such as supply and return temperatures, circuit pressure, compressor and pump protection levels are monitored via the display interface.
The total weight of the unit is 1 720 kg, dimensions L = 3 850 mm, W = 1 250 mm, H = 2 000 mm, which made it possible to place the chiller on a concrete platform without modification of the supporting structure. Connection is made through flexible compensators and ball valves DN65, which simplifies maintenance.
Equipment selection and direct co-operation with EVROPROM
The customer had already experienced the operation of a 256 kW Uniflair chiller through a service company. This is standard practice in Europe: 70 per cent of manufacturers initially entrust the selection, delivery and commissioning to third-party integrators. This approach reduces the risk of start-up errors, but limits flexibility when scaling up the plant.
The experience of Ūkė, UAB has shown that when expanding production with two additional extrusion lines and modernising thermoforming, direct work with the supplier is necessary to ensure that the parameters are precisely met. EVROPROM offered the optimal solution: a 241 kW Climaveneta NX SL K 0914T chiller with two independent R410A refrigerant circuits, four Danfoss SH300/SH240 scroll compressors, an aluminium microchannel condenser, a shell-and-tube heat exchanger and a Lowara FCTE 65 hydronic module.
The equipment integration and preparation process included:
– Thorough inspection of the chiller by HVAC engineers: 12 test points, checking all compressors and fans;
– Testing of 8 key parameters: water and mains connection to check EER, flow, pressure and temperature variations;
– Cleaning, flushing and tightness checks;
– Customs clearance and payment of all EU taxes and duties, including import documentation;
– Loading, packing and preparation for transport with certificates, PFI and Packaging List;
– Maintenance before dispatch: check of hydraulics, pumps, fans, compressor control.
Additionally EVROPROM provided 12 months for the unit and key components: compressor group, condenser and heat exchanger. The documented condition of the equipment, test reports, passport and certificates give the customer full transparency of the service life and operational capabilities.
Technological nuances for the plastics industry
Cooling stability and production parameters:
– Extrusion lines operate with a feed rate of 160-180 kg/h and a melt temperature of 220 °C, where a tolerance of ±0.3 °C determines product quality. Thermoforming units up to 120 kW maintain a water temperature of 12-18 °C. With a deviation of 2 °C, the reject rate reaches 8-12 %, which translates into a monetary value of up to 2,500 € per shift.
Chiller capacity and redundant circuits:
– A 241 kW chiller with R410A refrigerant provides 15-20 % capacity reserve for two extrusion lines and three thermoforming units. The double refrigerant circuit with Danfoss SH300 and SH240 compressors enables line changeover in 3-5 minutes without any reduction in capacity.
Efficient heat exchange and integrated hydraulics:
–Microchannel aluminium condenser with 45 m² heat exchange area and 110-130 kPa pressure drop increases efficiency by 18-22 %. The 12 m² shell-and-tube heat exchanger ensures a stability of ±0.2 °C. The integrated Lowara FCTE 65 pump with a flow rate of 40-42 m³/h and a head of 260 kPa operates for 8-10 h without overheating. The hydraulic module is integrated into the control system, providing real-time monitoring of temperature, flow rate and water pressure.
Reliability and performance of the system:
– The unit’sengine hours exceed 18,000, which allows scheduling overhaul after 7-8 years of intensive operation. Equipment availability exceeds 98% and emergency shutdowns are reduced by 35-40% thanks to redundant circuits and an integrated control system. The inspection included 12 key parameters: tightness, pressure and compressor efficiency.
Maximum output with minimum energy consumption:
–After integrating the new chiller, the total capacity of the cooling system reached 482 kW and the water temperature was stable within ±0.3 °C. Line capacity increased by 9.8 %, with an increase in energy consumption of only 3.5 %. The site’s integral energy efficiency ratio rose from an EER of 2.9 to 3.2, and the cost of cooling dropped to 0.31 kW/h/kW. After the integration of the new chiller, the total capacity of the cooling system reached 482 kW and the water temperature was stable within ±0.3 °C. Line capacity increased by 9.8 per cent, with an increase in energy consumption of only 3.5 per cent. The site’s integral energy efficiency ratio rose from an EER of 2.9 to 3.2, and the cost of cooling fell to 0.31 kW/h/kW. With 24h/day operation and 250 working days per year, this saves approximately ≈ 18,000-20,000 € per year in electricity costs, while increasing productivity and reducing losses through stable temperatures.
Direct co-operation with EVROPROM allowed Ūkė, UAB:
– Reduce integration time from the typical 45-50 days to 17 days;
– Optimise the project cost by 8-12%, saving ≈ 5-6 thousand €;
– Get full control of installation and start-up, including hydraulics, water connection 40 m³/h and head 260 kPa, temperature range 12/7 → 35 °C, EER ≥ 3.1;
– Eliminate bureaucratic delays associated with intermediaries while maintaining high quality standards.
EVROPROM provides a complete turnkey solution, fully customised to the customer’s processes and compliant with European HVAC standards. Each chiller undergoes a detailed inspection with engineers: 8 key parameters are recorded – inlet water temperature 12-18 °C, ΔT ±0.3 °C, water flow 38-42 m³/h, head 260-280 kPa, humidity 54-56 % RH, noise level ≤70 dB(A) at 10 m, pipework tightness and stability of operation at partial loads 30-40 %. Logistics are fully integrated: customs clearance, European taxes and duties, packaging and labelling of each unit, PFI and technical list. Preparation time at the station 1-2 working days, packing and inspection 24 h. Delivery time to the customer is reduced from 5 weeks to 17 days.
Author of the article:
Svyatoslav Ovcharenko, Sales Manager
10.11.2025