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SCANDICCI - SSI Schaefer was in an expansion mode, but due to the water restrictions in place to cope with a severe drought, Schaefer needed a way to add 40 percent more cooling capacity without increasing water use.
Fortunately, the company found a solution in Frigel Ecodry, a unique, closed-loop process cooling system.
Water conservation measures require companies to significantly limit water use. The restrictions were difficult to meet with Schaefer’s previous process cooling system, a 500-ton cooling tower and 400-ton chiller that consumed huge amounts of water. So Schaefer began to explore process cooling alternatives for its facility, which makes refuse containers, returnable packaging and storage systems for all types of automated warehousing and distribution centers.
The closed-loop cooling system with the Ecodry proposed by FRIGEL appeared immediately as the solution: the evaporation process is completely eliminated and there is only a limited consumption of water for the adiabatic operation of the chamber during the hottest hours of Summer. In addition to this, thanks to the exclusive adiabatic chamber, the accumulation of calcium on the exchanger with the loss of efficiency, typical lack of closed-loop cooling systems is completely eliminated.
Following an introduction of the Ecodry, the advantages were clear—less water and energy consumption, increase in productivity and cleaner water. More specifically, SSI Schaefer is realizing 97 percent water savings. And in addition to overall system energy savings, is seeing a 15 percent reduction in energy costs from free cooling opportunities alone and 10 percent energy savings – on top of faster cycle times – from use of efficient press side Turbogel units over standard TCUS.
At Frigel, we’re committed to providing our customers, like SSI Schaefer, with the latest energy and water-saving solutions that positively impact the bottom line and environment. The Ecodry system gives a competitive edge for manufacturers.
The Ecodry not only played a role in meeting SSI Schaefer’s water conservation challenge, but also its heavy contamination problems due to bacterial growth and presence of sludge into its water. Fees for dumping the contaminated water were higher than the costs of the water consumption itself. The Ecodry’s ability to provide consistent clean water with nearly zero water loss was a clear benefit. The cooling plant is also able to monitor and troubleshoot problems via a web-based network, 24 hours per day, making it extremely efficient to run.
“The Frigel system allowed us to save dramatically on water, as well as circulate clean water continuously to our machinery – a critical attribute to our industry,” said Morris Marlow, Technical Manager of SSI Schaefer. “This plays a large role in our commitment to overall efficiency and quality, and through our products.”
With a modular and compact design, the Ecodry system today is available in self-draining version, without the need of glycol in the water. Other problems that the Ecodry System helped to solve are: scale accumulation and frequent maintenance hassles in traditional cooling systems. So by implementing the closed-loop Ecodry system, Schaefer successfully added cooling capacity while dramatically reducing maintenance and water use. Although the Charlotte water restrictions were lifted this spring, Schaefer continues to benefit from the lower costs and higher efficiency associated with its new system.
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