{"id":2338,"date":"2025-10-31T02:02:32","date_gmt":"2025-10-31T02:02:32","guid":{"rendered":"https:\/\/andely.us\/?post_type=succes-stories&p=2338"},"modified":"2025-10-31T02:02:32","modified_gmt":"2025-10-31T02:02:32","slug":"how-we-helped-a-plastic-injection-plant-cut-90-of-its-energy-consumption","status":"publish","type":"succes-stories","link":"https:\/\/andely.us\/?succes-stories=how-we-helped-a-plastic-injection-plant-cut-90-of-its-energy-consumption","title":{"rendered":"How We Helped a Plastic Injection Plant Cut 90% of Its Energy Consumption"},"content":{"rendered":"\n

$87,389 per year. <\/strong>That\u2019s how much a plastic injection molding plant is saving after optimizing its cooling system with a customized solution designed and implemented by Andely Solutions<\/strong>.<\/p>\n\n\n\n

This project reduced 90.5%<\/strong> of the energy used for hydraulic equipment cooling, extended hydraulic oil life, lowered maintenance costs, and improved overall production efficiency.<\/p>\n\n\n\n

Here\u2019s how we achieved it.<\/p>\n\n\n\n

The Cooling Challenge in the Plastics Industry<\/strong><\/h2>\n\n\n\n

If you run a plastic injection facility, you know that cooling is critical to maintaining process stability and productivity. Yet, in many plants, cooling systems often create more problems than they solve.<\/p>\n\n\n\n

Typical challenges include:<\/p>\n\n\n\n

    \n
  • Scale buildup and contamination in water circuits<\/li>\n\n\n\n
  • Frequent hydraulic system failures<\/li>\n\n\n\n
  • High energy consumption<\/li>\n\n\n\n
  • Reduced oil life due to inefficient cooling<\/li>\n<\/ul>\n\n\n\n

    In markets where electricity costs continue to rise \u2014 especially during hot months \u2014 these inefficiencies directly impact profitability and production continuity.<\/p>\n\n\n\n

    Diagnosis: What We Found<\/strong><\/h2>\n\n\n\n

    After a detailed on-site assessment, our engineering team identified two major issues:<\/p>\n\n\n\n

      \n
    1. Low energy efficiency:<\/strong>
      <\/strong>The plant relied on a single mechanical chiller to cool both molds and hydraulic systems, overloading its capacity and driving up consumption.
      <\/li>\n\n\n\n
    2. Excessive power use:<\/strong>
      <\/strong>The hydraulic cooling circuit alone required 860,932.80 kWh per year<\/strong>, representing one of the plant\u2019s highest operational expenses.<\/li>\n<\/ol>\n\n\n\n

      Our Solution<\/strong><\/h2>\n\n\n\n

      The Andely engineering team proposed a simple yet highly effective strategy: split the cooling system into two independent circuits<\/strong> for improved control and energy efficiency.<\/p>\n\n\n\n

      Here\u2019s what we implemented:
      \ufeff<\/p>\n\n\n\n

      \u2705 Eco Cool Water system (adiabatic dry cooler)<\/strong> dedicated exclusively to hydraulic circuit cooling.<\/p>\n\n\n\n

      \u2705 Reassignment of the existing chiller<\/strong> to handle mold cooling only.<\/p>\n\n\n\n

      \u2705 Full redesign of the hydraulic distribution system<\/strong> to eliminate leaks, pressure losses, and inefficiencies.<\/p>\n\n\n\n

      The full installation was completed in about four months<\/strong>, including the setup of a dedicated area for the adiabatic system.<\/p>\n\n\n\n

      Results: 90.5% Less Energy Consumption<\/strong><\/h2>\n\n\n\n

      The results were immediate and measurable:<\/p>\n\n\n\n

      Metric<\/strong><\/td>Chiller <\/strong><\/td>Eco Cool Water<\/strong><\/td><\/tr>
      Power consumption (kW\/h)<\/td>92.28<\/td>– <\/td><\/tr>
      Annual consumption (kWh\/year)<\/td>860,932.80<\/td>75,405.82<\/td><\/tr>
      Annual electricity cost (USD)<\/td>95,778.78<\/td>8,388.89<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n

      Total savings: $87,389 USD\/year<\/strong><\/p>\n\n\n\n

      Other key benefits:<\/p>\n\n\n\n

        \n
      • Extended hydraulic oil life thanks to stable temperature control<\/li>\n\n\n\n
      • Improved process reliability and uptime<\/li>\n\n\n\n
      • Lower maintenance costs and reduced downtime<\/li>\n<\/ul>\n\n\n\n

        Why This Strategy Works<\/strong><\/h2>\n\n\n\n

        Separating the cooling circuits allows each system to run under optimal conditions while using the most efficient technology for its purpose.<\/p>\n\n\n\n

        Andely\u2019s Eco Cool Water systems:<\/strong><\/p>\n\n\n\n

          \n
        • Operate without refrigerant gases or compressors<\/li>\n\n\n\n
        • Use adiabatic pre-cooling only when necessary, maximizing water and energy savings<\/li>\n\n\n\n
        • Eliminate biological risks like Legionella<\/em>, common in open cooling towers<\/li>\n\n\n\n
        • Require minimal maintenance and ensure long-term durability<\/li>\n<\/ul>\n\n\n\n

          Can Your Plant Achieve Similar Results?<\/strong><\/h2>\n\n\n\n

          Absolutely. This approach can be applied to any manufacturing facility<\/strong> that currently relies on chillers or cooling towers for process cooling.<\/p>\n\n\n\n

          At Andely Solutions<\/strong>, we help industrial clients:<\/p>\n\n\n\n

            \n
          • Reduce water and energy costs<\/li>\n\n\n\n
          • Optimize thermal processes<\/li>\n\n\n\n
          • Transition to sustainable HVAC-R systems<\/li>\n\n\n\n
          • Boost productivity and reliability across operations<\/li>\n<\/ul>\n\n\n\n

            Interested in learning how much your facility could save?  \ud83d\udc49 Request a free assessment<\/strong> or explore our Eco Cool Water<\/strong>, Turbocor chiller<\/strong>, and plastic injection cooling solutions<\/strong> to discover how we can help you modernize your plant\u2019s cooling performance.<\/p>\n","protected":false},"featured_media":2282,"template":"","meta":{"_acf_changed":false},"class_list":["post-2338","succes-stories","type-succes-stories","status-publish","has-post-thumbnail","hentry"],"acf":[],"yoast_head":"\nHow We Helped a Plastic Injection Plant Cut 90% of Its Energy Consumption - Andely<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/andely.us\/?succes-stories=how-we-helped-a-plastic-injection-plant-cut-90-of-its-energy-consumption\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"How We Helped a Plastic Injection Plant Cut 90% of Its Energy Consumption - Andely\" \/>\n<meta property=\"og:description\" content=\"$87,389 per year. That\u2019s how much a plastic injection molding plant is saving after optimizing its cooling system with a customized solution designed and implemented by Andely Solutions. This project reduced 90.5% of the energy used for hydraulic equipment cooling, extended hydraulic oil life, lowered maintenance costs, and improved overall production efficiency. 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