Automation of industrial cooling
Stable technology, radically lower energy costs
In a modern manufacturing plant, industrial cooling systems are responsible for a significant portion of energy consumption. Without stable and precise temperature control, there is no consistent product quality, while an outdated or poorly controlled cooling process silently but continuously burns through profits.
At Konkoly Electro, we don't just automatically turn compressors on and off. By integrating custom PLC controls and industrial sensors, we elevate cooling systems – whether chillers, cooling towers or complete hall cooling – to an Industry 4.0 level that simultaneously guarantees process safety and the achievement of ESG goals.
Energy efficiency without compromise
Traditional cooling controls often operate on a binary, on or off principle, which results in huge energy waste and rapid wear of mechanical components. We put intelligent technology behind the systems:
- Demand-based power control: With advanced PLC programming and variable frequency drives (VFD), we ensure that pumps and fans operate at exactly the power required by the technology at the given moment. There is no unnecessary power surplus, with digital models the heat generation and cooling demand of each equipment can be easily calculated, which can be immediately followed by the cooling capacity.
- Free cooling integration: Where external temperature conditions allow, the control automatically switches to extremely cost-effective cooling with ambient air, relieving the compressors.
Precision in the service of quality assurance
In many industries – such as the plastics industry (injection molding), metalworking or the food industry – even a tenth of a degree fluctuation in the cooling water temperature can lead to scrap. Our control cabinets and the PLC codes we write guarantee deterministic, precise temperature control. The built-in PID control algorithms not only react to temperature changes, but also adapt to the ambient temperature, predict and compensate for fluctuations in the heat load, so that production lines can always work with optimal parameters.
Data-driven monitoring and predictive maintenance
An unexpected cooling system shutdown can paralyze the entire production in an instant. With Industry 4.0 automation, cooling is no longer a dark horse, but a data-driven, integrated parameter of the entire process.
- Real-time diagnostics: The system continuously monitors pressure values, flow rates, temperatures and current consumption.
- Early error detection: If a filter starts to clog or the refrigerant level approaches a critical limit, the PLC control sends an alarm to maintenance personnel before an actual shutdown occurs, which can be immediately displayed in the enterprise management (MES/ERP) system.
- Measurable savings: Continuous data collection (data logging) makes energy consumption transparent, which is essential for compiling corporate ESG reports and sustainability audits.
Steps of the process:
- Negotiation, technical consultation
- Contract conclusion
- Project plan
- Electric Design
- Design jury
- Electric assembly
- Testing
- Documentation
- Transport
- On-site commissioning
- Education
- Remote monitoring
- Technical support
Get the most out of your existing or new cooling system!
Don't let uncontrolled or piecemeal cooling reduce your profits and jeopardize your production. Request a technical consultation and let's design an intelligent, data-driven and energy-saving cooling control together with Konkoly Electro engineers!