Case Study
Process Chiller Installation Supporting Sustainable Chocolate Research
Overview
Client: Long-standing manufacturing research client (name withheld)
Industry: Food manufacturing and product research
Project Overview: Newsome supplied and installed a new process chiller for a chocolate manufacturing research facility, providing a reliable chilled water supply that met sustainability goals and suited a live research setting. As the project developed, the system was redesigned to support additional specialist equipment while maintaining stability, efficiency, and protection of the refrigeration plant.
Newsome was appointed to supply and install a new process chiller to support a chocolate manufacturing research facility operated by one of its longest-standing clients. The brief focused on delivering a reliable source of chilled process water while aligning with the client’s established sustainability objectives and allowing for future flexibility within a live research environment. The installation was required to support sensitive test equipment used within the client’s product development and research activities. As the project progressed, the scope evolved to accommodate additional specialist equipment, prompting a system redesign to ensure operational stability, efficiency and protection of the refrigeration plant.
The Challenge
The client’s initial requirement was for chilled water to be supplied directly from the process chiller to individual pieces of test equipment. While technically viable, this approach presented several operational risks as the facility expanded its research capability. New specialist equipment introduced during the project required frequent connection and disconnection from the chilled water circuit. This presented potential issues around temperature stability, hydraulic disruption and mechanical stress on the chiller, particularly during repeated start-stop conditions.
In addition, the client required assurance that the system would remain protected during periods of low load and colder ambient conditions, while maintaining alignment with their environmental commitments and long-term sustainability strategy.
The Solution
Newsome supplied and installed a process chiller operating on R290 hydrocarbon refrigerant, a natural refrigerant with a very low Global Warming Potential. This refrigerant choice supported the client’s green credentials while delivering high efficiency and stable temperature control for research applications. To address the evolving operational requirements, Newsome retrofitted a primary and secondary heat exchange system into the chilled water circuit. This approach decoupled the chiller from the downstream research equipment, allowing the refrigeration plant to operate continuously at optimal conditions, regardless of changes on the secondary side.
The introduction of the heat exchanger enabled the chiller circuit to remain hydraulically stable, reducing the risk of temperature fluctuations, pressure spikes or mechanical wear associated with frequent equipment changes. On the secondary side, flexibility was increased, allowing specialist research equipment to be connected and disconnected without impacting chiller performance.
As part of the system upgrade, Newsome also introduced an anti-freeze glycol solution within the circuit. This provided frost protection, improved resilience during low ambient conditions and added an extra layer of security for both the chiller and associated pipework.
Engineering Considerations
The system was designed to prioritise efficiency, reliability and long-term serviceability. By maintaining constant flow and load conditions through the primary circuit, the chiller operates within its optimal performance envelope, reducing cycling and improving compressor longevity. The use of a primary and secondary heat exchange arrangement also improves system controllability, enabling precise temperature regulation for sensitive research processes while protecting the refrigeration plant from variable downstream demands.
The selection of R290 refrigerant further enhanced the system’s environmental performance, delivering excellent thermodynamic efficiency while supporting compliance with current and future refrigerant legislation.
Installation and Commissioning
Newsome managed the full installation and commissioning process, ensuring minimal disruption to the client’s ongoing research activities. The system was tested under varying load conditions to confirm stable operation, effective heat transfer and reliable frost protection. Close collaboration with the client’s technical team ensured that the final configuration met both current operational needs and anticipated future requirements.
Outcome and Benefits
The completed installation provides the client with a robust, efficient and future-proof chilled water solution that supports their research operations without compromising sustainability objectives. Key benefits delivered include improved system efficiency through continuous chiller operation, enhanced operational flexibility for changing research equipment, reduced mechanical stress on the refrigeration plant, and increased resilience through glycol-based frost protection.
The use of a natural refrigerant reinforces the client’s commitment to environmentally responsible engineering while positioning the facility for long-term compliance with evolving environmental standards.
Conclusion
This project demonstrates Newsome’s ability to adapt system design in response to changing client requirements, delivering technically sound and sustainable solutions for specialist process environments.
By combining low-GWP refrigeration technology with intelligent hydraulic design, Newsome has provided a reliable chilled water system that supports innovation, efficiency and environmental responsibility within a demanding research setting.