Case Study: Central Cooling Solution at Nebula Surgical
Customer Overview
Nebula Surgical is a leading manufacturer of orthopedic surgical products. Their facility houses multiple precision CNC machines and sensitive areas where orthopedic implants are finished and packed. For a company that prioritizes quality, controlling the work environment is critical.
Challenge
With the growing number of CNC machines in operation, the production area at Nebula Surgical was becoming increasingly hot. The high internal temperatures made it uncomfortable for staff and also started to affect the performance of the machines.
Alongside this, the warm and humid environment was taking a toll on the products themselves. The orthopedic components, which need to remain spotless, were showing signs of corrosion during the finishing stages — something unacceptable for medical-grade products.
Solution
After a detailed study of the site, we provided a custom-designed Central Cooling System that addressed heat and humidity issues in one integrated solution.
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Cooling Tower + Water-to-Air Heat Exchanger:
We installed a system where water cooled in the cooling tower is circulated to indoor water-to-air heat exchanger units through a closed-loop pipeline. These units transfer the coolness from the water directly into the air, lowering room temperatures efficiently. -
High Energy Efficiency:
This design reduces the load on traditional chillers, leading to significantly lower energy consumption. -
Simple Maintenance:
With fewer moving parts and a straightforward layout, the system is easy to service, ensuring uninterrupted operation. -
Improved Air Quality & Moisture Control:
By lowering the temperature, the system naturally reduced excess moisture in the air as well. This created a stable and cleaner environment without requiring separate dehumidifiers. -
Uniform Distribution:
Custom ducting ensured cool, fresh air reached every part of the CNC section and product handling areas.
Implementation
The project was planned and executed in phases so that Nebula Surgical’s production was not disrupted. All equipment, piping, and ducting were installed to blend seamlessly into the facility’s layout.
Process Flow:
Cooling tower–cooled water → Piped to indoor water-to-air heat exchanger units → Cool air circulated across CNC and product handling areas.
Results & Benefits
| Parameter | Before | After |
|---|---|---|
| Temperature | 30–35°C | 25–27°C |
| Humidity & Corrosion Risk | High | Significantly Lower |
| Operator Comfort | Low | High |
| Machine Stability | Fluctuating | Stable |
| Product Quality | Inconsistent | Consistently High |
| Energy Consumption | High | Reduced |
Key Outcomes:
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Product Quality Improved: Surface corrosion issues were eliminated.
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Better Working Conditions: Comfortable temperatures increased staff efficiency.
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More Reliable Machines: CNC machines now run with better stability.
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Highly Energy Efficient: Cooling tower + water-to-air design reduced power usage.
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Low Maintenance: Simple, robust system for long-term reliability.
Conclusion
By installing a high-performance central cooling system with a cooling tower–based water-to-air heat exchanger, Nebula Surgical successfully solved its overheating issue while also curbing humidity-related problems — without the need for separate dehumidification equipment. The result is a stable, clean, comfortable, and energy-efficient environment that supports both product quality and production efficiency.
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