Case Study
Delivering High-Performance Process Cooling for Induction Welding in North Carolina
A UK-based induction welding company, specialising in high-performance welding solutions, was commissioned to supply critical equipment to Kanthal—a global leader in industrial electric heating technology and resistance materials—at their facility in North Carolina, USA. Given the precision and reliability required for Kanthal’s operations, the company needed a robust and efficient cooling solution to support their welding equipment.
The system had to deliver consistent 180kW cooling capacity at 480V / 60Hz while maintaining 8 bar hydraulic pressure at 15°C, ensuring optimal performance and preventing overheating. Additionally, the client required built-in redundancy to safeguard against downtime and prioritised energy efficiency to reduce operational costs without compromising performance.
The Challenge
The system needed to deliver 180kW of cooling capacity with an optional backup in the unlikely case case of failure.
Additionally, it had to maintain 8 bar of hydraulic pressure at 15°C while prioritising energy efficiency to reduce operational costs.
The Solution
To meet these precise requirements, Evolution Cooling Ltd designed, supplied, installed, and commissioned a dual-chiller system consisting of 2 x ZCF 1220 180kW chillers. Key system features included:
Key Highlights Of The Solution
✅ 480V /50Hz 180kW Chiller Supplied by Evolution Cooling Ltd
✅ Dual pump system to maintain 8 bar pressure
✅ Plate heat exchanger for efficient heat transfer
✅ Fan speed control for optimised energy usage
✅ Soft start contactors to reduce electrical surges
✅ 500-litre buffer tank for system stability
✅ R410a refrigerant for high efficiency and compliance with regulations
Our team travelled to North Carolina to carry out the installation and commissioning, ensuring a seamless and timely execution.
The Results
💡 Delivered ahead of schedule – completed within six weeks from order
⚙️ System performed exactly as required, meeting both OEM and end-customer expectations
🌍 Energy-efficient design reduced operational costs while ensuring compliance
🔧 Flawless installation process with no disruption to operations
”The client was highly impressed with the fast delivery, system performance, and our engineers’ technical expertise on-site. The project was completed on time and exceeded expectations, reinforcing Evolution Cooling Ltd’s reputation for reliability and innovation in industrial process cooling.
KanthalProjects Manajer
For businesses in need of top-tier chiller maintenance and parts replacement services
If you need a reliable and energy-efficient cooling solution tailored to your process, or expert support with chiller installation, maintenance, or parts replacement, we’re here to help. Get in touch today—call us at 0121 820 8946 or email [email protected]. 🚀
