Project summary: In 2025, GESON supplied a 750 kW central cooling system for ten PVC pipe extrusion lines in Bangladesh. The factory operates continuously, 24 hours a day and seven days a week, in ambient temperatures reaching 52°C. The solution combines five 150 kW water-cooled screw chillers, ten square open-type cooling towers and twenty water pumps.
Project at a Glance
| Location | Bangladesh |
|---|---|
| Project year | 2025 |
| Application | Central process cooling for 10 PVC pipe extrusion lines |
| Operating schedule | 24 hours/day, 7 days/week |
| Maximum ambient temperature | 52°C |
| Total cooling capacity | 750 kW / approximately 213 RT |
| Chillers | 5 × 150 kW water-cooled screw chillers |
| Compressors | Hanbell screw compressors |
| Chilled-water temperatures | 12°C return / 7°C supply |
| Refrigerant | R407C |
| Power supply | 3-phase, 400 V, 50 Hz |
| Heat rejection | 10 square open-type cooling towers |
| Pumps | 20 water pumps |
The Customer’s Cooling Challenge
The customer operates ten PVC pipe extrusion lines on a continuous production schedule. The previous chillers no longer delivered sufficient cooling, which slowed production and reduced operating efficiency. The replacement system also had to cope with a maximum local ambient temperature of 52°C while maintaining a stable 7°C chilled-water supply.
Because all ten lines depend on process cooling, the project required more than a simple one-for-one equipment replacement. The factory needed a central system with enough total capacity for sustained duty, practical capacity staging and an equipment arrangement that could be serviced without concentrating the entire cooling load in a single chiller.
GESON’s 750 kW Central Cooling Solution
GESON configured the system around five 150 kW water-cooled screw chillers. Each chiller uses a Hanbell screw compressor and R407C refrigerant and is designed for 12°C return water and 7°C chilled-water supply. Together, the five chillers provide 750 kW of nominal cooling capacity, equivalent to approximately 213 refrigeration tons.
The complete project supply comprised:
- five 150 kW water-cooled screw chillers;
- ten square open-type cooling towers;
- twenty water pumps; and
- electrical configuration for 3-phase, 400 V, 50 Hz power.
Dividing the load among five chillers gives the factory a modular platform for its ten production lines. Chiller capacity can be staged according to the active process load, while an individual unit can be isolated for inspection or service. The exact sequence and redundancy available at any moment depend on the site’s final piping, control logic and current production demand.
Why Water-Cooled Screw Chillers?
This application combines a high total process load, continuous operation and demanding ambient conditions. A water-cooled system transfers condenser heat through a separate condenser-water circuit to the cooling towers. This arrangement is appropriate for sustained industrial cooling duties where stable process-water temperature and centralized heat rejection are required.
For PVC pipe extrusion, controlled water temperature and flow support the vacuum sizing and cooling stages. Stable cooling conditions help the production line maintain repeatable processing conditions. Final pipe output and quality still depend on the material formulation, tooling, line settings, water distribution and operating procedures, so cooling equipment should be selected as part of the complete process rather than in isolation.
Cooling Towers and Pump Packages
The project included ten square open-type cooling towers and twenty water pumps to support the condenser-water and chilled-water circuits. Supplying the chillers, towers and pumps as one coordinated package allowed the equipment quantities, operating temperatures and electrical standard to be reviewed together before delivery.
Manufacturing and Delivery Evidence
The photographs on this page show the chillers during factory assembly and pre-shipment preparation, together with packaged pumps and cooling-tower equipment. They document the equipment supplied for the project; they are not presented as photographs taken at the customer’s Bangladesh production site.
Operating Result
After the new system entered operation, the customer reported improved production efficiency compared with the previous underperforming chillers. No percentage improvement is stated because verified before-and-after production measurements were not provided.
This result illustrates the practical value of matching total cooling capacity, chilled-water temperature, heat rejection and circulation equipment to a multi-line PVC extrusion plant instead of treating the chiller as a standalone component.
Information Needed for a Similar PVC Extrusion Project
For a reliable technical selection, provide the following information:
- number and type of extrusion lines;
- plastic material and pipe production range;
- line throughput, where available;
- required process-water supply and return temperatures;
- required water flow and pressure;
- daily operating hours and maximum ambient conditions;
- site design wet-bulb temperature for cooling-tower selection;
- local voltage, frequency and phase;
- water quality and available installation space; and
- required redundancy and future expansion plans.
Related Process-Cooling Resources
- Water-Cooled Chiller Systems
- Industrial Chillers for Plastics Processing
- How to Choose a Chiller for Plastics Processing
- Oman PVC Injection Molding Chiller Project
Frequently Asked Questions
What cooling capacity was supplied for the Bangladesh PVC extrusion project?
The total supplied cooling capacity was 750 kW, approximately 213 refrigeration tons, divided across five 150 kW water-cooled screw chillers.
How many PVC extrusion lines does the system support?
The central cooling system was specified for ten PVC pipe extrusion lines operating 24 hours per day, seven days per week.
What chilled-water temperatures were specified?
The system was configured for 12°C return water and 7°C chilled-water supply.
Why were five chillers used?
The modular arrangement allows cooling capacity to be staged for a multi-line production load and allows individual units to be isolated for inspection or service. The final operating sequence depends on the site’s control and piping design.
What equipment was included?
The project supply included five water-cooled screw chillers, ten square open-type cooling towers and twenty water pumps, configured for 3-phase, 400 V, 50 Hz power.
Did the new system improve production?
Yes. The customer reported improved production efficiency after the previous chillers, which had insufficient cooling performance, were replaced. No unverified percentage improvement is claimed.
Planning a Central Cooling System for PVC Extrusion?
Send GESON your number of lines, material, throughput, target water temperature, operating schedule, ambient conditions and power supply. Our engineering team will review the required cooling capacity and system configuration for your project.
