Aerospace Manufacturer – Multi-Site Cooling Tower Modernisation | Vistech
Multi-Site Cooling System Modernisation Delivering Efficiency, Sustainability and Risk Reduction
A leading UK aerospace manufacturer commissioned Vistech Cooling Systems to modernise cooling infrastructure across four operational sites. Legacy systems had become inefficient, unreliable and costly to maintain, with high water consumption and elevated Legionella risk.<br />
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Vistech implemented a phased, data-driven upgrade strategy, replacing outdated open-loop cooling systems with closed-circuit adiabatic solutions. The project delivered substantial reductions in energy usage, water consumption and operational costs, while improving system reliability and aligning with corporate sustainability targets.
The Challenge
The client operated multiple UK manufacturing sites, each with legacy cooling systems that had evolved through years of modification and partial upgrades. This resulted in fragmented system design, poor integration between components and reduced overall efficiency.
The ageing infrastructure led to frequent breakdowns, increasing maintenance costs and impacting production reliability. Cooling performance was inconsistent, and the lack of clear system design data made optimisation and future planning difficult.
Water consumption was a major concern, with open cooling systems requiring significant volumes of make-up water and ongoing chemical treatment. This conflicted with the organisation’s sustainability objectives and contributed to rising operational costs.
Additionally, the presence of open water systems introduced an elevated risk of Legionella, requiring stringent compliance measures, continuous monitoring and ongoing chemical dosing.
Economic pressures further compounded these challenges, with short-term maintenance interventions delivering diminishing returns and failing to address underlying system inefficiencies.
The Solution
Vistech deployed a structured, data-led approach to system modernisation, beginning with detailed performance monitoring to establish true cooling demand across each site. This enabled targeted upgrades prioritising the highest-impact opportunities.
The primary solution involved the replacement of open-loop cooling systems with closed-circuit adiabatic coolers, significantly improving efficiency while reducing water usage and eliminating Legionella risk.
Key Technical Features:
Closed-circuit adiabatic cooling systems reducing water consumption and removing the need for open water treatment
High-efficiency pump sets with variable speed control to deliver demand-led operation and energy savings
System rationalisation, replacing multiple tanks, cooling towers and continuously running pumps with a simplified, optimised configuration
New pipework infrastructure improving system integration, reliability and maintainability
Performance monitoring and data-driven optimisation enabling accurate system control and future scalability
The modernised systems deliver stable, efficient cooling performance while significantly reducing operational complexity and maintenance requirements.
Programme
System Analysis
Performance monitoring and data capture to determine true cooling demand
Adiabatic Cooling
Design and installation of closed-circuit adiabatic coolers
Pump Systems
Supply and installation of variable speed pump sets
Pipework
Design and installation of new pipework infrastructure
System Rationalisation
Removal and consolidation of redundant tanks, towers and pumps
Controls & Optimisation
Implementation of demand-led control strategies
Commissioning
Testing, validation and optimisation of system performance
“The modernisation of our cooling systems has delivered significant improvements in efficiency, reliability and sustainability across our sites. The reduction in water and energy consumption, combined with improved system control, has provided measurable operational and financial benefits.”
— Engineering & Operations Team, Aerospace Manufacturer