Load dynamics
Machines, tool cooling and thermal processes generate loads that change quickly. The system must control stably at full load and part load, even when lines start up and shut down.
Industrial cooling for
your production
Planning, plant engineering and service from a single source
We build the process cooling for your production
KSI Kältetechnik plans and builds systems for industrial cooling: central refrigeration, chillers and cooling water networks that supply machines, tools and production processes with the process cooling they need. With natural refrigerants, designed with redundancy and matched to the load profile of production.
We take on the new construction of the plant room, the expansion as production grows and the Modernisation of existing systems. For Uponor in Zella-Mehlis, we built a central cooling and heating plant without halting plastics production.
Process cooling is more than cooling capacity. What matters is how precisely the system holds temperatures when machines start up and shut down, and how much of the extracted heat can be reused. That is why we prefer to be involved from the design stage.
Four requirements
What we measure every system against
Temperature accuracy
Any deviation in temperature management can affect product quality, cycle times or component accuracy. What counts is how tightly the system holds the supply temperature over long periods.
Availability
If the cooling stops, production often stops too. Redundant pumps and chillers and a concept for maintenance during operation are therefore part of the design from the start.
Efficiency
Process cooling often runs around the clock. Free cooling, heat recovery and controls that follow actual demand determine the operating costs.
What we use for this
What we build: process cooling as one system
Industrial cooling covers very different tasks, from cooling individual machines to the central cooling supply of an entire plant. We plan them as one overall system of generation, distribution and control.
Chillers and central refrigeration
Chillers, dry coolers, pumps and hydraulics designed as one system and matched to the temperature levels of the consumers. At this scale, the system structure determines energy consumption.
Machine and tool cooling
Cooling water at the temperature and volume that machines and tools need, from a central network instead of many individual units. This reduces maintenance effort and power consumption.
Free cooling
At low outdoor temperatures, the outside air takes over part of the work. The higher the required supply temperature, the more hours per year the compressor runs less or not at all.
Heat recovery and heat pump
The heat from cooling can be used for heating and process heat. At Uponor, the cold and warm sides of the heat pump work simultaneously: the system cools and heats in one.
Natural refrigerants
Propane (R290), ammonia (NH₃) and CO₂ instead of synthetic refrigerants, which the F-Gas Regulation is gradually restricting. This secures operation and service over the entire service life of the system.
Conversion during ongoing operation
The new plant room is built alongside the existing one, and the switchover only happens afterwards. This keeps production running during construction.
From practice
Uponor, Zella-Mehlis
For Uponor's plastics production in Zella-Mehlis, KSI built a central cooling and heating plant for the production processes, alongside ongoing production and without downtime.
- Refrigerant R290 (propane)
- Cooling capacity 2 × 318 kW
- Heating capacity 2 × 403 kW
- Redundancy 100%, all pumps redundant
- Mode of operation Cooling, heating and free cooling mode according to current demand
- Control Siemens central control system with secure remote access
Another example: for TÜV SÜD Industrieservice in Munich, we modernised the cold and warm brine system for testing and industrial applications, with 2 MW of cooling capacity. To the TÜV SÜD reference
To the Uponor referenceSo you know whether we are a good fit for each other
Our project sizes
Where we work
We work where the cooling supply of a production facility is solved centrally: a dedicated plant room, a chilled water or brine network, several consumers and requirements for redundancy and efficiency. Typically in the three- to four-digit kilowatt range.
Where the boundary lies
You can get a single process chiller for one machine directly from the manufacturer. As soon as several consumers, a cooling water network or heat recovery come into play, it is worth talking to us.
Further reading
From load profile to concept
How we develop a sound concept from operating data, load profiles and temperature levels is described on our planning page. Which natural refrigerant suits which application is shown in our overview.
New line, expansion or refurbishment of an existing system?
We look at the load profile, temperature levels and existing system and develop a concept that fits your production, with sound assumptions on free cooling, heat recovery and redundancy.
More from KSI Kältetechnik
Matching services
Planning & Concept DesignEnergy analysis, system design and conception with natural refrigerants.Find out moreRevitalisation & ModernisationEfficiently converting and modernising existing systems to natural refrigerants.Find out moreInstallation & commissioningProfessional plant engineering and safe commissioning of industrial refrigeration systems.Find out moreTechnical Support & MaintenanceMaintenance, 24/7 service and maintenance for reliable system operation.Find out moreNatural refrigerantsCO₂, ammonia and propane at a glance: characteristics, safety and use in industrial refrigeration.Find out moreRefrigeration technology for data centresRefrigeration supply for continuous operation: chilled water network, free cooling, redundancy and conversion during ongoing operation.Find out moreRefrigeration for pharma and laboratoriesTight temperature tolerances, redundant design, ready for validation and fully documented.Find out moreReference projectsRealised refrigeration systems with natural refrigerants – from data centre to hospital.Find out moreSectorsRefrigeration solutions for industry, data centres, clinics, hospitality, food & more.Find out more