Cast & Alloy |variable speed chiller's | Precision Cooling for hard and soft Anodising

Case Study: Precision Cooling for Anodising – Cast and Alloy’s Partnership with Himalaya Refrigeration Industries

Customer: Cast and Alloy
Industry: Aluminum Forging & Aluminum Castings
Application: Hard & Soft Anodising Process
Products Supplied:

• 15 TR Variable Speed Water Chiller

• 5 TR Fixed Speed Water Chiller

Background

Cast and Alloy is a reputed manufacturer specializing in aluminum forging and aluminum casting components for critical industrial applications. As part of their surface treatment process, anodising plays a vital role in enhancing corrosion resistance and improving aesthetic finishes. Both hard anodising and soft anodising processes are highly temperature-sensitive and require precise and uninterrupted cooling to maintain bath stability and achieve uniform quality.

Challenge

During anodising, the exothermic reaction between the electrolyte and aluminum workpiece causes a rapid rise in bath temperature. Cast and Alloy was facing inconsistent cooling performance with their old setup, resulting in:

• Temperature fluctuations during anodising

• Non-uniform coating thickness

• Increased rejection rates

• High power consumption during low-load conditions

They required a reliable cooling solution that could:
✔ Maintain consistent temperature under varying load
✔ Operate efficiently across multiple anodising lines
✔ Offer flexibility between hard and soft anodising operations

Solution by Himalaya Refrigeration Industries

After a detailed process analysis, Himalaya Refrigeration Industries recommended and supplied:

1. 15 TR Variable Speed Water Chiller

   • Application: Main cooling for the anodising bath

   • Technology: Inverter-based compressor to modulate cooling capacity

   • Advantage: Energy savings during partial load and precise temperature control

2. 5 TR Fixed Speed Water Chiller

   • Application: Backup/secondary chiller for light-duty anodising or as standby

   • Advantage: Robust, simple-to-maintain unit for consistent cooling

Results & Benefits

• ✅ Enhanced Cooling Precision: Tight temperature control improved coating uniformity

• ✅ Reduced Energy Costs: Variable speed chiller reduced power usage by 20–25% during partial loads

• ✅ Increased Productivity: Minimized downtime due to overheating

• ✅ Better Process Flexibility: System designed to switch efficiently between hard and soft anodising

• ✅ Long-Term Reliability: Himalaya chillers designed for rugged anodising environments

Customer Testimonial

"With Himalaya's cooling system, we now have full control over our anodising temperature. Their technical team understood our process thoroughly and delivered a solution that improved our quality and reduced costs."
— Mr Dipenbhai , Cast and Alloy

Conclusion

By adopting Himalaya Refrigeration Industries’ customized cooling solution, Cast and Alloy has significantly improved its anodising process efficiency, product quality, and operational reliability. This partnership reflects Himalaya’s commitment to delivering energy-efficient, process-specific chilling solutions across the metal finishing industry.