$87,389 per year. That’s 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.
Here’s how we achieved it.
The Cooling Challenge in the Plastics Industry
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.
Typical challenges include:
- Scale buildup and contamination in water circuits
- Frequent hydraulic system failures
- High energy consumption
- Reduced oil life due to inefficient cooling
In markets where electricity costs continue to rise — especially during hot months — these inefficiencies directly impact profitability and production continuity.
Diagnosis: What We Found
After a detailed on-site assessment, our engineering team identified two major issues:
- Low energy efficiency:
The plant relied on a single mechanical chiller to cool both molds and hydraulic systems, overloading its capacity and driving up consumption. - Excessive power use:
The hydraulic cooling circuit alone required 860,932.80 kWh per year, representing one of the plant’s highest operational expenses.
Our Solution
The Andely engineering team proposed a simple yet highly effective strategy: split the cooling system into two independent circuits for improved control and energy efficiency.
Here’s what we implemented:
✅ Eco Cool Water system (adiabatic dry cooler) dedicated exclusively to hydraulic circuit cooling.
✅ Reassignment of the existing chiller to handle mold cooling only.
✅ Full redesign of the hydraulic distribution system to eliminate leaks, pressure losses, and inefficiencies.
The full installation was completed in about four months, including the setup of a dedicated area for the adiabatic system.
Results: 90.5% Less Energy Consumption
The results were immediate and measurable:
| Metric | Chiller | Eco Cool Water |
| Power consumption (kW/h) | 92.28 | – |
| Annual consumption (kWh/year) | 860,932.80 | 75,405.82 |
| Annual electricity cost (USD) | 95,778.78 | 8,388.89 |
Total savings: $87,389 USD/year
Other key benefits:
- Extended hydraulic oil life thanks to stable temperature control
- Improved process reliability and uptime
- Lower maintenance costs and reduced downtime
Why This Strategy Works
Separating the cooling circuits allows each system to run under optimal conditions while using the most efficient technology for its purpose.
Andely’s Eco Cool Water systems:
- Operate without refrigerant gases or compressors
- Use adiabatic pre-cooling only when necessary, maximizing water and energy savings
- Eliminate biological risks like Legionella, common in open cooling towers
- Require minimal maintenance and ensure long-term durability
Can Your Plant Achieve Similar Results?
Absolutely. This approach can be applied to any manufacturing facility that currently relies on chillers or cooling towers for process cooling.
At Andely Solutions, we help industrial clients:
- Reduce water and energy costs
- Optimize thermal processes
- Transition to sustainable HVAC-R systems
- Boost productivity and reliability across operations
Interested in learning how much your facility could save? 👉 Request a free assessment or explore our Eco Cool Water, Turbocor chiller, and plastic injection cooling solutions to discover how we can help you modernize your plant’s cooling performance.
