Central Cooling System for Silver Jewellery Manufacturing Facility
Customer: Aman Jewel Art Private Limited
Located in the industrial hub of Rajkot, Aman Jewel Art Pvt. Ltd. is a leading manufacturer of silver jewellery, specializing in casting, melting, polishing, stone setting, electroplating, CNC engraving, laser cutting, and precision finishing processes.
The company operates multiple production floors with high manpower density and continuous heat-generating processes such as silver melting furnaces, induction heating systems, buffing motors, polishing stations, and electroplating lines. During peak summer conditions in Gujarat, maintaining a comfortable and stable working environment became a major operational challenge.
The Challenge
The customer’s old manufacturing building consists of 3 production floors equipped with approximately 185 TR of indoor cooling load.
The ground floor experiences extremely high heat generation due to:
- Silver melting furnaces
- Heating ovens and induction systems
- Electroplating heaters
- Continuous polishing and finishing operations
- High occupancy and machinery density
The upper floors have comparatively lower heat loads depending on production activity and shift timing. The customer required:
- Uniform cooling across all floors
- Energy-efficient operation during partial load conditions
- Reliable cooling performance in harsh summer climate
- Lower maintenance requirements
- Better indoor air quality for worker comfort and product handling
- Stable temperature conditions for jewellery finishing and polishing operations
In addition, the company constructed a new 3-floor production building with an additional 75 TR indoor cooling requirement, demanding a scalable and dependable central cooling solution.
The Solution
A customized Central Cooling System was designed and supplied using:
- High-performance Indoor Cooling Units (ICUs)
- Variable speed vertical multistage pumping system
- Oversized cooling tower
- Closed-loop cooling water circulation system
- Industrial-grade filtration and electrical safety systems
The complete system was engineered specifically for jewellery manufacturing applications where dust, heat, humidity, and process consistency are critical factors.
Key Features of the Supplied System
Heavy Duty Indoor Cooling Units
The supplied FCUs were specially designed for industrial cooling applications and included:
- Large surface area cooling coils
- Heavy thickness copper tubes for long operational life
- High-efficiency heat transfer design
- Easy-clean washable filters
- High dust holding capacity filters suitable for polishing dust and industrial particles
- High-quality axial fans for uniform airflow and low noise operation
The robust FCU construction ensures reliable operation even in demanding manufacturing environments containing metallic dust and continuous process heat.
Variable Speed Vertical Multistage Pumping System
One of the major engineering considerations was varying cooling demand across different floors.
Since the ground floor consistently experiences maximum heat load while upper floors may require reduced cooling during certain production periods, a Variable Frequency Drive (VFD) operated vertical multistage pump with IE3 efficiency motor was installed.
Benefits Achieved:
- Constant pressure with variable flow operation
- Automatic adjustment based on actual cooling demand
- Significant energy savings during partial load conditions
- Reduced water wastage and hydraulic stress
- Stable cooling performance across all floors
- Lower electrical consumption compared to constant-speed systems
This intelligent pumping arrangement allowed the system to dynamically respond to real-time cooling requirements.
Closed Loop Cooling Water Circuit
The cooling tower water is circulated through the fan coil units in a closed-loop system, providing several operational advantages:
- Cleaner water circulation
- Reduced scaling and contamination
- Extended life of coils and pumps
- Lower maintenance frequency
- Better heat transfer efficiency
- Improved system reliability
To further protect the system, an industrial-grade water line filtration system was installed to continuously remove suspended particles and impurities.
Oversized Cooling Tower Design
Considering Rajkot’s harsh summer temperatures, the cooling tower was intentionally selected with oversized capacity.
Advantages of Oversizing:
- Better cooling tower approach temperature
- Improved cooling during peak summer conditions
- Stable chilled water temperatures
- Reduced stress on pumps and ICUs
- Improved long-term reliability
- Lower fan loading and extended equipment life
Even under derated summer operating conditions, the system continues to deliver efficient cooling performance.
Electrical Safety & Protection
Industrial-grade electrical safety systems were incorporated for reliable and safe operation.
Protection Included:
- MPCB protection for pumps and cooling tower fans
- Heavy-duty contactors
- Overload and short-circuit protection
- Safe motor operation under fluctuating conditions
This ensures uninterrupted operation and enhanced equipment safety in continuous production environments.
Operational Benefits Achieved
After implementation of the central cooling system, Aman Jewel Art Pvt. Ltd. experienced significant improvements in both production environment and operational efficiency.
Major Benefits
Improved Worker Comfort
Stable indoor temperatures reduced heat stress for workers involved in polishing, assembly, and precision jewellery handling.
Better Product Quality
Controlled temperature and improved air circulation enhanced working conditions for delicate jewellery finishing and polishing operations.
Reduced Humidity During Summer
The continuous air circulation and cooling effect helped reduce uncomfortable humid conditions common during Gujarat summers, improving operator productivity and workplace comfort.
Energy Savings
The variable flow pumping system optimized power consumption during partial load operation.
Lower Maintenance
Closed-loop circulation and filtration significantly reduced coil choking, scaling, and maintenance downtime.
Reliable Multi-Floor Cooling
The system successfully managed varying heat loads across different production floors without compromising cooling performance.
Long Equipment Life
Heavy-duty copper coils, oversized cooling tower, and industrial-grade components ensured durability and long-term operational reliability.
Project Summary
| Parameter | Details |
|---|---|
| Customer | Aman Jewel Art Private Limited |
| Location | Rajkot, Gujarat |
| Industry | Silver Jewellery Manufacturing |
| Existing Building Cooling Load | 185 TR |
| New Building Cooling Load | 75 TR |
| System Type | Central Cooling with ICUs |
| Pump Type | Variable Speed Vertical Multistage Pump |
| Cooling Medium | Closed Loop Cooling Tower Water |
| Key Features | Heavy Duty ICUs, VFD Pumping, Oversized Cooling Tower, Industrial Filtration & Electrical Safety |
