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Energy optimization in industrial cooling: consumption savings and increased efficiency

Context and objective

In the plastics manufacturing and processing sector, cooling is a crucial step in the production process. However, traditional cooling power generation involves high electricity consumption, significantly affecting operating costs.

The company set itself the goal of structuring a more efficient cooling system capable of reducing the energy requirements needed to produce cooling energy, optimizing consumption and improving the sustainability of the entire production process.

The intervention

To achieve this goal, a groundwater cooling system was implemented, which takes advantage of the direct injection of water into the cooling circuits. This system enables direct cooling of the die and mold lines, providing higher efficiency than conventional cooling systems.

The intervention included:

1

Use of groundwater for direct cooling

Elimination of the need for chiller power generation, reducing electricity consumption.

2

Optimized cooling of production lines

Water is fed directly into the circuits, improving thermal control and process efficiency.

3

Reducing energy impact

Partial elimination of the use of energy-intensive refrigeration units.

The total investment for the intervention was €620,000, with a significant economic return due to the savings achieved.

Results and benefits

Adoption of the new system has brought measurable economic and operational benefits:

Savings of more than 220,000 €/year

Through the reduction of electricity consumption.

Obtaining 884 TEE/year

with an economic value of about 84,000 €/year.

Economic and operational impact

Drastic reduction in energy costs

Lower expenses related to refrigeration power generation.

Increased operational efficiency

Faster and more effective cooling of production lines.

Economic recovery through incentives

The TEEs obtained enable a further reduction in the payback time of the investment.

Environmental Sustainability

The use of groundwater reduces environmental impact compared to traditional refrigeration systems.

The adoption of a groundwater cooling system was a strategic choice for the company, resulting in significant economic savings and improving the overall efficiency of the production process. The intervention demonstrates how resource optimization can translate into concrete benefits in terms of both operating costs and environmental sustainability.

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