Summit Systems Case Study: Energy Efficiency and Cooling System Upgrade for Fisher Plastics

Fisher Plastics, based in Huddersfield, UK, is a leading toolmaker and moulder in the plastic injection moulding industry. Its extensive product range includes producing components for the automotive, medical, building services, education and leisure sectors. A key element of its process is to keep the hydraulic power packs and moulds cool while manufacturing its product range.

(Pictured: Nigel Hallet from Summit Process Cooling, with Kelly Autey, CEO for Metalliform Group Limited, parent company for Fisher Plastics Ltd.)

The company faced challenges with its existing chiller system, which consumed significant amounts of energy to cool both the moulds and hydraulic oil circuits. Rising energy costs were putting financial pressure on the business, and reliance on a single, large chiller created a risk of operational downtime. Failures in the chiller system had already resulted in production losses due to the lack of a backup system. Fisher Plastics sought a solution to enhance energy efficiency, improve system reliability, and reduce operational costs.

Summit Process Cooling proposed an innovative upgrade to address these challenges. The solution included replacing the outdated Bluebox chiller with an adiabatic cooler for hydraulic oil and throat cooling while repurposing the Industrial Frigo chiller exclusively for mould cooling. This approach utilised existing equipment effectively, minimising waste while optimising resource use.

One of the key design elements was the integration of a new adiabatic cooler, which offered free cooling for the Industrial Frigo Chiller during low ambient temperatures. This significantly reduced reliance on the chiller’s compressors, lowering energy costs and extending equipment lifespan. To facilitate seamless operation, a plate heat exchanger (PHE) was installed between the two cooling circuits, aided by a 3-way temperature control valve to automatically pre-cool water returning from the moulds, via the adiabatic cooling system in low ambient conditions. The use of glycol in the adiabatic cooling circuit provided frost protection, while the moulded circuit remained glycol-free to avoid losses and shop floor slip hazards through possible spillages during frequent mould changes.

The upgrade also involved replacing outdated carbon steel piping with stainless steel pipework to eliminate corrosion risks. A buffer tank and separate pipework circuits were installed to serve the hydraulic oil coolers, while a duplex filtration system removed particulates and maintained water quality for the process.

An advanced HMI touchscreen with visualisation control system, automated operations, rotating duty and standby pumps for even wear. The PLC software monitored key parameters like return water and ambient temperatures, ensuring optimal energy use by switching to free cooling when possible.

The installation was carried out with minimal disruption, thanks to close collaboration between Fisher Plastics’ management and Summit’s experienced team. The new system brought immediate improvements. Annual energy savings of 357,667 kWh—equivalent to £150,220—were achieved, representing a 90% reduction in energy consumption compared to the original system. During low ambient conditions, only 6.5 kW of energy was required to meet a 200kW cooling demand, delivering an impressive coefficient of performance of 30.7.

The system’s environmental impact was also reduced by eliminating glycol from the mould cooling circuit. Additionally, operational reliability was enhanced through the use of standby pumps and separate cooling circuits, reducing production downtime risks. Free cooling further lowered operational costs and extended the chiller’s lifespan by reducing its workload.

Jonathan Hill, Group Technical Manager for Metalliform Group Limited, the parent company of Fisher Plastics commented, “The new system has been a game-changer in terms of efficiency and performance. It has drastically improved the chilled water supply to the machinery within our factory, ensuring that optimal and consistent process temperatures are maintained while reducing our energy consumption. We’ve already noticed a significant decrease in our utility bills, thanks to the system’s energy-saving features.

The installation was done with minimal disruption to our operations and considering we undertook this project in the Christmas period when resources were low, Summit pulled out all of the stops to get us fully operational by January startup. The technicians were extremely knowledgeable and integrated with our site maintenance team to get the project delivered in a timely manner. The system has been designed in a user-friendly way and the training provided ensured all our staff know how to fully utilise the system.

Additionally, we have had multiple visits from the team after installation to ensure we are fully happy with the results which has shown to us that Summit really cares about the product they have supplied and our satisfaction with the new installation. We are very happy with our new chiller system and would highly recommend Summit to anyone in need of a reliable, efficient & energy-saving solution.”

Summit Process Cooling will provide ongoing support and maintenance, with remote monitoring to ensure optimal performance. The system was designed for scalability, with provisions for a 25% capacity increase and space for an additional chiller if needed.

This upgrade has delivered substantial energy savings, improved reliability, and a reduced environmental footprint. By incorporating energy-efficient technologies and optimising existing resources, Summit Process Cooling provided Fisher Plastics with a future-proof solution that meets both current and long-term cooling requirements.

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