TE Connectivity has improved cooling efficiency and reduced energy consumption at its Hastings site through a free cooling project delivered with ICS Cool Energy.
The global manufacturer uses process cooling to support injection moulding operations, where stable temperatures are critical to maintaining machine performance and product quality. Having worked with ICS Cool Energy on temperature control for a number of years, TE Connectivity was looking for an opportunity to upgrade older equipment and introduce free cooling to improve efficiency and reduce operating costs.
By installing a new system with free cooling capability, ICS Cool Energy helped TE Connectivity reduce chiller run-time, lower electricity consumption and improve reliability across a critical manufacturing process. The project has also given the business a strong platform for wider sustainability improvements, with the free cooling approach now being considered at other TE Connectivity sites.
Challenge
At TE Connectivity’s Hastings facility, process cooling plays an essential role in supporting injection moulding operations. Cooling is used to control temperatures around the moulding process, including heated tools, barrels and other critical machine components, helping to prevent overheating and maintain stable operating conditions.
For a manufacturing process that depends on temperature stability, any loss of cooling performance creates operational risk. If temperatures rise too far, machines can alarm and stop, affecting production continuity and potentially product quality.
As TE Connectivity looked to reduce energy use and improve environmental performance, the Hastings team wanted a more efficient solution that would not only improve reliability, but also use low ambient conditions to reduce mechanical cooling costs during cooler periods of the year.
Solution
Building on its existing relationship with the site, TE Connectivity approached ICS Cool Energy to upgrade the moulding process cooling system and integrate free cooling capability.
The project included the installation of a set of run standby chillers, both able to work alongside the free cooler. This arrangement gives the site both resilience and flexibility, allowing units to be alternated to support servicing and routine maintenance.
The free cooling system reduces reliance on compressor-driven mechanical cooling by using lower ambient temperatures to assist the process whenever conditions allow. At TE Connectivity, this has enabled the site to cut energy use significantly, particularly during cooler months, while maintaining the temperatures required for injection moulding operations.
Results
The project has delivered both operational and energy-saving benefits for TE Connectivity. By installing new chillers with free cooling, the site has improved the reliability of a critical utility supporting its injection moulding process, while also reducing electricity consumption.
“We’ve seen energy bills come down drastically, and the system has been running very well. Free cooling has been a major factor. The chillers are usually running at 60 to 80 kilowatts, while in winter, the free cooler is running at around 5 kilowatts. That’s a massive difference. Just as importantly, the support from ICS has been strong throughout, and that has helped build confidence in the solution,” said Benjamin Hall, Maintenance & Facilities Manager at TE Connectivity.
Alongside lower energy use, the new system has helped maintain more consistent process conditions, reducing the risk of overheating and unplanned stoppages on moulding machines.
The success of the installation has also had an impact beyond the Hastings site. As a sustainability champion within the business, Benjamin Hall has been using the project as an example when discussing energy-saving opportunities at other TE Connectivity locations in the UK and Europe.
“Energy use and environmental performance are both major priorities for us, so being able to show what free cooling can deliver in a live manufacturing environment is really valuable. It is something I have been keen to promote at other sites because the difference in energy demand is significant,” Benjamin Hall said.
Rod Avery at ICS Cool Energy added: “This project highlights the value of free cooling in helping manufacturers reduce energy use and support stable process conditions. By working closely with TE Connectivity, we were able to upgrade critical cooling infrastructure and deliver a solution that improves reliability while supporting longer-term sustainability goals.”
For more information on ICS Cool Energy and its complete range of process temperature control solutions, please visit www.icscoolenergy.com.
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