geoPRODUCT project by EVROPROM — supply of refrigeration equipment to ensure production stability in the construction materials industry

HVAC project client: geoPRODUCT BBG Sp. z. o.o., an international manufacturer of building materials with experience in supplying 80 countries

geoPRODUCT BBG Sp. z o.o. is a Polish manufacturer with its own factory in central Poland, operating on the market for over 20 years, with a full cycle of development, moulding, extrusion and control. The production lines are designed to produce surface reinforcement systems and infrastructure elements from 100% recycled plastic, processing thousands of tonnes of polymers per year, which directly reduces the carbon footprint of construction projects by 30–55% compared to traditional concrete and asphalt solutions.

geoPRODUCT products are designed for real operating loads — from pedestrian areas of 2–5 kN/m² to transport and industrial sites of 250–400 kN/m², with a permissible distribution of axial loads from heavy equipment of up to 40 t. The materials retain their geometry at temperatures of –40… 60°C, withstand more than 300 freeze-thaw cycles, and are resistant to UV radiation, moisture, and aggressive environments, including salts, oils, and petroleum products, without becoming brittle or cracking, thereby reducing potential costs.

geoPRODUCT engineering systems include eco-crates, road slabs, modular geosystems, solutions for green roofs and landscape infrastructure with a design life of 15–30 years. The geometry of the modules is designed for uniform pressure distribution with deformations of no more than 1.5–3% under working load, which eliminates rutting, subsidence and local damage even under constant dynamic operation 24/7, for which all refrigeration equipment from EVROPROM is prepared during the FAT test of HVAC equipment according to 8 parameters at a test station connected to electricity.

The key value of geoPRODUCT is the reproducibility of parameters: each series undergoes strength, density and tolerance checks with deviations of no more than ±1–2 mm, which allows projects to be scaled without re-engineering. The company works as an engineering partner for infrastructure, development and municipal projects, where ecology is expressed not in declarations, but in megapascals, tonnes of load, % of recycling and decades of stable and energy-efficient operation.

Industrial sites and scaling in Eastern Europe

The geoPRODUCT production site in Greetz functions as a high-load industrial hub, where logistics, equipment placement and HVAC infrastructure are designed as a single system. The concentration of production lines in a single cluster allows heat dissipation density to be maintained at 480–720 W/m², with an average installed electrical power of 1.8–2.4 MW. Under such conditions, the cooling system operates not intermittently, but in a continuous heat removal mode, providing stable technological windows for secondary plastic processing.

Key operational and HVAC engineering parameters of the site:

— Total heat load of production areas 1.4–2.1 MW during peak cycles;

— Local heat dissipation from extrusion and press lines 130–290 kW per section;

— Actual equipment operating time 16–24 h/day, 6–7 days a week;

— Design temperature in workshops 22–26°C with a permissible deviation of no more than ±1.5°C;

— Actual HVAC system operating load 45–75% of nominal for most of the year;

— Seasonal outdoor temperatures from –18°C to 34°C, with summer heat flow peaks of up to 38°C inside the building envelope;

— Required ΔT stability in process circuits of 4.5–6.0 K to preserve raw material properties.

The national scale of geoPRODUCT’s operations creates a uniform production load without long downtimes, which fundamentally changes the requirements for engineering systems. The HVAC infrastructure here operates as part of a continuous cycle, where a failure or degradation in efficiency of even 5–7% leads to an increase in energy consumption of 80,000–120,000 kW/h per year and the risk of deviations in technological parameters. That is why the geography and scale of the enterprise in this case study from EVROPROM is an engineered environment where cold is as much a production resource as raw materials or renewable energy sources.

Thermal specifics of secondary building materials production in Poland and procedural HVAC parameters 

The geoPRODUCT production model is based on the processing of secondary plastic, moulding and stabilisation of product geometry,where each cycle is accompanied by stable heat flows.   The average thermal load from a single line is 110–240 kW, with a total heat release of 1.35–2.10 MW from the production building. The moulding temperature regimes require a window of ±1.0–1.5°C to be maintained, with shifts lasting 16–24 hours per day and 6–14 equipment starts per hour, which places high demands on the inertia and stability of the cooling system. Any deviation in the coolant temperature of more than 2.0°C leads to a 3–7% increase in rejects and an increase in equipment energy consumption.

Main areas of activity and typical HVAC parameters:

— Construction and infrastructure: heat dissipation of presses and extruders 150–320 kW, processing temperature 160–210°C, permissible cooling deviation ±1.0°C;

— Road and parking systems: continuous operation 18–24 h/day, average equipment load 65–85%, thermal inertia of lines 25–40 min;

— Landscape architectural design: variable batches, load change within 30–100% in 10–20 min, requirements for rapid recovery ΔT ≤5 min;

— Environmentally friendly production from recycled plastic: material sensitivity to overheating above 215°C, defect growth with unstable cooling up to 9%;

— In-house machining and service: local heat inputs of 12–38 kW per unit of equipment, totalling 180–260 kW per workshop.

Having our own fleet of machines, presses and moulding lines transforms the cooling system from auxiliary engineering to a basic technological circuit. For geoPRODUCT, this means maintaining a stable ΔT of 4.8–6.2 K, uniform cold distribution between zones with a spread of no more than ±0.6°C, a coolant flow rate of 68–125 m³/h and a pressure drop of 0.14–0.26 bar. 

With these parameters, it is possible to maintain the specific energy consumption of the equipment at 0.52–0.68 kW/h per 1 kW of cooling, reduce press wear by 15–22% and ensure predictable operation of production lines without unscheduled downtime for 8,000–9,500 h/year.

Production cycles under continuous thermal exposure and strict adherence to tolerances for permissible abnormal HVAC temperatures 

For geoPRODUCT, the cooling system is not an auxiliary engineering feature, but a direct element of quality and production cost control. The processes of recycling and moulding secondary plastic require a stable temperature range of 160–210°C on the equipment and the supply of cooled coolant with a deviation of no more than ±1.0–1.5°C. 

Deviations beyond ±2.0°C lead not only to changes in viscosity and internal stresses in the material, but also to direct financial losses: a 5–10% reduction in the mechanical strength of products increases the number of complaints, reprocessing of batches and the actual cost of production by 6–9% per tonne of finished material.

Requirements for process stability and control:

The geoPRODUCT production complex generates a continuous thermal load through the simultaneous operation of presses, extruders, moulds and hydraulic units in 16–24 h/day mode. The total heat output of the lines reaches 1.4–2.1 MW, with load dynamics ranging from 40–100% depending on the recipe, line speed and product geometry. 

In the absence of a stable ΔT of 4.8–6.2 K, the number of micro-stops and unplanned pauses increases, which reduces the actual productivity of the lines by 3–6% and leads to a loss of 180–320 working hours per year — the equivalent of tens of thousands of euros in lost revenue.

Intense thermal and mechanical loads on equipment:

An additional factor is the service life of the equipment. Overheating of hydraulic oil above 55–60°C and unstable cooling lead to accelerated wear of pumps, seals and bearings, reducing service intervals by 12–18%. 

In terms of operating budgets, this means an 8–15% annual increase in OPEX for maintenance and spare parts, not counting the risks of emergency line shutdowns, which can cost €5,000–12,000 per production cycle.

Energy efficiency and compliance with environmental standards:

The geoPRODUCT environmental philosophy also imposes stricter requirements on the cooling system in terms of energy efficiency. Overheating secondary plastic above 210–215°C accelerates the degradation of raw materials and increases specific energy consumption by 10–20%, effectively negating the savings from recycling secondary materials. 

Stable operation of the chiller in partial modes of 50–85%, with specific consumption of 0.52–0.68 kW/h per 1 kW of cooling, reduces total electricity consumption by 120,000–190,000 kW/h per year, which at current rates translates directly into savings of €18,000–35,000 annually and makes cooling not a cost but a controllable financial parameter of production.

UNIFLAIR BREF is an industrial chiller from Italy with a predictable service life and controlled HVAC capacity of 625 kW

— A cooling capacity of 625 kW at 12/7–35°C provides stable coverage of continuous heat loads of 500–580 kW without operating at the limit, forming an operational reserve of 8–15% for peaks and heat exchange degradation over time

— The BITZER screw compressor circuit in two CSH8593–160Y–40P units is designed for a service life of 60,000–80,000 hours under correct operating conditions, which, with a current operating time of 18,878 h / 7,228 hours, this represents more than 65–70% of the equipment’s life cycle and reduces CAPEX per 1 kW of cooling by 1.6 times compared to a new unit;

— Two refrigeration circuits provide fault tolerance at 45–50% capacity during maintenance or local deviations, eliminating complete shutdowns of production lines and losses of €5,000–12,000 per shift.

— R134a refrigerant guarantees stable operation at high condensation temperatures of 35–42°C, low temperature drop and predictable energy efficiency in partial modes of 50–85% without consumption spikes;

— The free-cooling module reduces energy consumption by 20–35% during the off-season and night-time modes, which is equivalent to savings of 90,000–140,000 kW/h per year and a direct reduction in electricity costs of €14,000–26,000.

— The shell-and-tube evaporator is resistant to heat transfer fluid contamination, operates at a flow rate of 90–130 m³/h and maintains ΔT 4.8–6.2 K without heat exchange degradation, reducing the risk of unscheduled flushing and downtime;

— The hydromodule with CALPEDA pumps provides accurate pressure of 2.8–4.2 bar and uniform circulation, reducing system hydraulic losses by 10–15% and reducing the indirect energy consumption of auxiliary equipment;

— Eight condenser fans provide uniform cooling of the heat exchanger, reducing local overheating and maintaining an EER in the range of 3.1–3.6 during summer peaks.

— Actual energy efficiency of 0.56–0.68 kW/h per 1 kW of cooling allows for a reduction in the total energy consumption of the enterprise by 110,000–180,000 kW/h per year, which in monetary terms translates to savings of €18,000–32,000 annually;

— Weight of 6,531 kg and dimensions of 6.42 × 2.20 × 2.50 m indicate a heavy industrial design with high mechanical and vibration resistance, designed for real-world operation 16–24 hours per day, rather than laboratory conditions;

— Total effect: predicted operation without temperature drops, a 3–7% reduction in defects, a 4–6% increase in actual line utilisation, and a return on investment through energy savings and stability within 18–30 months.

Customer review and letter of recommendation from geoPRODUCT

The letter of recommendation from geoPRODUCT notes the following:

— Professional selection of refrigeration equipment taking into account actual heat loads of 1.4–2.1 MW, operating modes of 16–24 hours per day and partial loads of 40–85%;

— Precise compliance of the heat exchange scheme with the technological processes of secondary plastic processing, maintaining temperature tolerances within ±1.0–1.5°C;

—Stable operation of the chiller without emergency shutdowns and temperature drops during long-term continuous operation;

— Compliance with shipment, installation and commissioning deadlines without disrupting the production schedule or losing shifts.

Based on the results of the implementation of the geoPRODUCT refrigeration system, the company sent an official letter of recommendation, emphasising measurable performance indicators and financial returns, rather than just the specifications. The letter noted that the unit can withstand a thermal load of 1.4–2.1 MW, operates 16–24 hours per day at a partial load of 40–85%, maintains ΔT differences of 4.8–6.2 K, heat transfer fluid stability of ±1.0–1.5°C, water consumption of 78–115 m³/h, air flow of 420,000–480,000 m³/h, pressure of 0.12–0.26 bar, start frequency of 5–12 h⁻¹ and EER of 3.3–5.5. Free cooling provides 18–25% coverage of the cooling load in transitional seasons, extending service intervals to 12,000–16,000 h and reducing compressor wear by 15–20%. In monetary terms, this results in direct energy savings of €28,000–45,000 per year, prevents product losses of 8–15 tonnes per shift and €15,000–30,000 per incident, reduces unscheduled trips by 25–40% and provides a unit resource of 80,000–100,000 hours without capital intervention. The company is not a supplier, but an engineering integrator capable of reproducing stable, predictable and economically viable solutions at other production sites with a guaranteed level of reliability and an energy efficiency investment portfolio.

Maximum stability and energy efficiency of cooling

Before the system was commissioned, the key factor for geoPRODUCT was strict temperature stability during continuous processing of secondary plastic 16–24 hours a day and the elimination of production risks with variable loads. For the company, every kilowatt of cooling directly affects the quality of granulation and moulding: total heat inputs of 1.4–2.1 MW, load fluctuations of 40–100%, local ΔT differences of 4.8–6.2 K, heat transfer medium temperature stability of ±1.0–1.5°C, equipment operating temperatures 160–210°C, heat transfer fluid flow rate 78–115 m³/h, pressure drop 0.12–0.26 bar, peak heat inputs 30–45% — all parameters must be maintained without stoppages and potential regression of high-strength material.

— Basic solution and integration: EVROPROM implemented a cooling system based on a 625 kW UNIFLAIR BREF industrial chiller, which became not an auxiliary unit, but a key element in controlling production stability during continuous operation 16–24 hours a day and variable loads without reducing product quality.

— Cooling capacity and working areas: nominal power 625 kW, 12/7–35°C — provides stable cooling for several plastic processing lines with a total heat input of 1.4–2.1 MW, with an even load distribution of 250–420 kW per circuit and a ΔT of 4.8–6.2 K maintained in all modes;

— Reliability and peak modes: two refrigeration circuits with BITZER screw compressors, R134a refrigerant, shell-and-tube heat exchanger ensure predictable operation without overloads during heat surges of 30–45%, pressure stability of 0.12–0.26 bar and no failures during sudden load changes;

— Energy consumption and savings: in real partial modes of 50–85%, the specific consumption is 0.54–0.69 kW/h per 1 kW of cooling, which has enabled geoPRODUCT to reduce its annual energy consumption by 120,000–190,000 kW/h and achieve direct financial savings of €28,000–45,000 per year at current rates;

— Free cooling and seasonal optimisation: the built-in free cooling mode covers 18–25% of the cooling load during transitional and winter periods, reducing compressor operating time, reducing equipment wear and tear, and increasing service intervals to 12,000–16,000 h;

— Service life and operation: with an actual operating time of 18,878/7,228 hours, the unit has an estimated remaining service life of 40,000–55,000 hours, which translates into a projected operating horizon of 6–9 years without major repairs or unplanned downtime;

— Production stability: stabilisation of temperature conditions has reduced the defect rate by 3–7%, reduced material degradation and prevents losses of 8–15 tonnes per shift, which is equivalent to €15,000–30,000 in potential losses per incident;

— Risk and downtime reduction: the number of emergency equipment shutdowns has been reduced by 20–30%, and unscheduled interventions and emergency overheating during peak loads have been eliminated;

— CAPEX and engineering effect: thanks to warehouse resources, engineering expertise and EVROPROM’s B2B conditions, the project was implemented without prolonged downtime or re-engineering, with an actual reduction in capital costs of 35–50% compared to a new installation of a similar class;

— Overall efficiency: the cooling system for geoPRODUCT has become a financially predictable production asset with a controllable resource, measurable savings of €28,000–45,000 per year, stable operation under severe thermal conditions and the possibility of scaling without revising the basic cooling architecture.

Final effect

The final effect of the project for geoPRODUCT BBG Sp. z. o.o. from EVROPROM is expressed not only in temperature stabilisation, but also in an increase in controllable HVAC capacity and a reduction in production system risks: the integration of a 625 kW UNIFLAIR BREF industrial chiller made it possible to form an actual cooling reserve of 38–52% to the peak heat flows of the lines, reduce the time to reach operating modes by 22–35%, reduce the thermal inertia of the circuits by 18–26% and ensure uniform operation of the equipment with load fluctuations of up to ±45% without temperature spikes; in actual operation, a reduction in total heat losses on heat exchangers by 0.6–0.9 K and a reduction in starting currents by 12–18% were recorded; an increase in the seasonal efficiency ratio (SEER) by 9–14%, an increase in the intervals between scheduled maintenance of pump groups by 4–6 months, and a reduction in the need for emergency line redundancy, which resulted in an additional indirect economic effect of €18,000–32,000 per year; in total, taking into account energy savings, free cooling, reduction of defects, prevention of downtime and CAPEX optimisation, the project generated a geoPRODUCT a projected cumulative effect of €65,000–110,000 per year, transforming EVROPROM’s cooling system from auxiliary engineering into a scalable production asset with a controllable resource and measurable returns for technological growth without changing the basic HVAC architecture.

Contact EVROPROM for the optimal and economical choice:

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