Project summary: GESON supplied a 155 kW (44 RT) water-cooled screw chiller system for a PVC injection molding plant in Oman. The system serves six injection molding machines operating 24 hours a day, seven days a week, under local ambient temperatures reaching 50°C.
Oman PVC Injection Molding Cooling Project at a Glance
| Project year | 2023 |
|---|---|
| Application | PVC injection molding |
| Injection molding machines | 6 machines |
| Operating schedule | 24 hours/day, 7 days/week |
| Maximum ambient temperature | 50°C |
| Chiller type | Water-cooled screw chiller |
| Cooling capacity | 155 kW / 44 RT |
| Chilled-water temperatures | 12°C return / 7°C supply |
| Refrigerant | R407C |
| Electrical supply | 440 V / 50 Hz |
| System scope | Chiller, cooling tower and circulating pumps |
The Client’s Cooling Challenge
PVC injection molding requires stable mould cooling to remove process heat and maintain repeatable production cycles. At this Oman plant, six injection molding machines run continuously. The process-cooling system therefore needed to support a sustained industrial load rather than intermittent production.
Oman’s extreme summer conditions added another engineering consideration. With local ambient temperatures reaching 50°C, the heat-rejection system needed to remain dependable during demanding operating conditions.
The project requirements included:
- cooling capacity for six injection molding machines;
- stable 7°C chilled-water supply during 24/7 operation;
- a solution designed for local ambient temperatures up to 50°C;
- compatibility with the plant’s 440 V / 50 Hz electrical supply; and
- a coordinated water-cooled package including the chiller, cooling tower and pumps.
GESON’s 155 kW Water-Cooled Screw Chiller Solution
GESON configured a complete process-cooling package centered on a 155 kW (44 RT) water-cooled screw chiller. The project scope included the cooling tower and circulating pumps required for the chilled-water and condenser-water loops.
Key System Components
- 155 kW / 44 RT water-cooled screw chiller: provides stable process chilled water for the six injection molding machines.
- Cooling tower: rejects condenser heat from the water-cooled system.
- Chilled-water and cooling-water pumps: circulate water through the process and condenser loops.
- Siemens touchscreen control interface: allows operators to monitor operating conditions and system status.
Chilled-Water Design Condition
The system was configured for 12°C return water and 7°C supply water, representing a 5°C temperature difference. Based on the disclosed 155 kW capacity and temperature difference, the calculated design chilled-water flow is approximately 26.7 m³/h. Final pump selection must also account for piping resistance, equipment pressure drop and the approved project layout.
For a different plant, use GESON’s injection molding chiller sizing guide or submit the actual machine and process data for engineering selection.
Why a Water-Cooled Screw Chiller Was Selected
The plant’s continuous process load and extreme local summer conditions made dependable heat rejection essential. A water-cooled screw-chiller configuration is well suited to sustained industrial cooling duties. Supplying the chiller, cooling tower and pumps as a coordinated package also helps align water flow, condenser performance and control requirements.
Learn more about GESON’s water-cooled industrial chiller systems.
Factory Inspection and Testing
Before shipment, the chiller was inspected and tested at the GESON factory. The project photographs document the complete unit, screw compressor assembly, heat exchangers, electrical control cabinet, Siemens touchscreen and operating instrumentation.
Project Result
After the cooling system entered operation, the customer reported being very satisfied with the solution and stated that production efficiency improved substantially. This is qualitative customer feedback; no unverified percentage improvement or energy-saving figure has been added to this case study.
The project information was reviewed with Mr. George, General Manager at GESON.
Frequently Asked Questions
What size chiller was supplied for this injection molding project?
GESON supplied a 155 kW (44 RT) water-cooled screw chiller for the PVC injection molding plant.
How many injection molding machines does the chiller serve?
The cooling system serves six injection molding machines operating 24 hours per day, seven days per week.
What ambient temperature was considered?
The maximum local ambient temperature provided for the Oman project was 50°C.
What chilled-water temperature was used?
The system was configured for 12°C return water and 7°C supply water.
What equipment was included?
The project scope included the water-cooled screw chiller, cooling tower and circulating pumps.
Can GESON size a chiller for another injection molding plant?
Yes. Selection should consider the number and tonnage of the molding machines, polymer type, cycle time, mould cooling load, hydraulic-oil load, ambient conditions and operating schedule. See our complete injection molding chiller solution.
Request an Injection Molding Cooling-System Selection
Send GESON the number and clamping force of your machines, plastic material, hourly production, required water temperatures, maximum ambient temperature, voltage and operating hours.
