Sustainable Cooling System – Fail-Safe and Future-Proof

The objectives for this project were crystal clear. First and foremost, the new installation had to guarantee uninterrupted climate control, without the need to temporarily shut down the existing installation. This required a fail-safe solution, ensuring that at least one cooling machine is always available.

Additionally, the client wanted to focus heavily on sustainability and energy efficiency. The old installation needed to be replaced by a system that reduces energy consumption and makes optimal use of natural resources – in this case: outdoor air cooling.

Finally, the lifespan and future-proofing were also important. The installation not only had to function reliably for years but also intelligently address maintenance challenges, such as the condition of the roof on which the system was to be placed.

To realize these ambitions, Industrial Air Company developed a fully prefabricated installation in their own workshop. Here, the system was first completely assembled and tested, ensuring that everything could be mounted flawlessly on-site in one go – and it showed: the installation was captured on video in just 51 seconds.

The installation is designed to be fail-safe: if one machine fails, temperature regulation continues uninterrupted. Additionally, a hybrid cooling system was chosen that primarily operates on outdoor air. Only when necessary do inverter-controlled compressors engage, which very precisely adjust the cooling capacity and require minimal inrush currents.

This smart technology makes the installation significantly more energy-efficient than the previous system. Moreover, the entire engineering process – from heat load calculation to software development – was handled by IAC. The on-site assembly was also carried out in-house.

During the project, the roof was also included in the sustainability approach. Although the roof was still in good condition, IAC advised preventive maintenance to be carried out before installing the system. This means the installation won’t need to be removed for roof work in the next 20 years – a smart investment in the future.

The new cooling system provides both immediate and long-term benefits. Thanks to the fail-safe design and the use of outdoor air cooling, the indoor climate is guaranteed 24/7, with significantly lower energy consumption. The inverter technology ensures stable control behavior and minimal peak load.

The prefab approach enabled extremely fast assembly, with minimal impact on ongoing business processes. And thanks to the proactive consideration of the roof, the installation is now future-proof without additional interventions.