Industrial Cooling Upgrade for Aerospace Manufacturer in the UK

Overview: A leading manufacturing company serving the aerospace market, with four distinct sites
across the UK identified a critical need to modernise its outdated cooling infrastructure. Each facility was
equipped with cooling systems which, over successive years, had become technically
outdated and operationally inefficient.

Client Challenges

1. Aging Infrastructure:

Over time, various modifications, including the addition and removal of equipment, had been made to these systems. This led to inefficiencies, frequent breakdowns, and increased maintenance costs.

• Poor integration between system elements
• Reduced reliability and frequent failures
• High maintenance costs and production inefficiencies

2. Excessive Water Consumption

The company’s cooling systems consumed large volumes of water, contradicting their sustainability targets and inflating operational costs through high water treatment and replenishment demands.

3. Legionella Risk

Open water systems significantly increased the risk of Legionella outbreaks, posing:

• A serious health and safety hazard
• Continuous chemical treatment requirements
• Increased compliance and monitoring costs

4. Unknown Cooling Requirements

Historic system alterations had obscured true system specifications and performance levels. This ambiguity:

• Complicated maintenance and optimisation
• Hindered planning for future upgrades or capacity expansions

5. Rising Economic Pressures

• Operational inefficiencies and outdated systems created growing financial strain
• Short-term fixes delivered diminishing returns on investment

Our Solution

Vistech Cooling Systems deployed a strategic, data-driven approach, initiating detailed performance monitoring to quantify actual cooling demands at each facility. Work began at the site presenting the greatest potential for improvement.

System Modernisation Measures:

• Adiabatic Cooler Installation: Replacing traditional open-loop systems with closed adiabatic coolers, dramatically reducing water consumption and eliminating Legionella risk.
• Pipework & Variable Speed Pump Set: New pipework and a high-efficiency pump set with variable speed control ensured consistent, demand-led performance and energy savings.
• System Rationalisation: A consolidated system replaced two tanks, one cooling tower, and six continuously running pumps, streamlining operations and reducing maintenance.

Environmental & Financial Impact

1. Energy Efficiency

• Annual electricity savings: 410,515 kWh

2. Water Conservation

• Annual water savings: 1,834 m³

3. Financial Returns

• Estimated annual savings: £70,000
• Payback period: 2.2 years, factoring in reduced chemical and maintenance spend

4. Sustainability Impact

• Major reduction in environmental footprint
• Aligned with long-term corporate ESG goals

Why Vistech?

This case study highlights the measurable benefits of upgrading industrial cooling systems with Vistech Cooling Systems. By integrating energy-efficient, low-maintenance, and environmentally conscious technologies, the aerospace manufacturer has not only reduced costs but also safeguarded its operational continuity and sustainability commitments.