Central Cooling Solution for Printing Industry

Customer: Printwell Offset

Location: Aji GIDC

Printwell Offset is a well-established printing company engaged in high-volume offset printing operations for packaging materials, labels, commercial prints, and industrial printing applications.

The company operates advanced printing machinery on the top floor production area spread across approximately 6700 sq. ft. The facility is constructed with sheet metal roofing, which absorbs intense solar heat during summer, significantly increasing indoor temperatures and creating uncomfortable working conditions for both manpower and machinery.

In addition to solar heat gain, continuous operation of offset printing machines, dryers, compressors, and electrical equipment further elevated the shop floor temperature, affecting operator comfort, print quality consistency, and machine performance.

To overcome these challenges, HIMALAYA Refrigeration Industries designed and supplied a 105 TR Central Cooling System specially engineered for industrial printing applications.

The Solution

The installed system consists of:

✅ 105 TR Central Cooling Plant
✅ Heavy-duty Indoor Cooling Units
✅ Variable Speed Vertical Multistage Pumping System
✅ Closed Loop Cooling Water Circulation
✅ Industrial-grade Air Distribution System

The solution was designed to deliver uniform cooling throughout the production area while maintaining energy-efficient operation during varying production loads.

Key Features of the System

High Performance Indoor Cooling Units

Specially designed Indoor Cooling Units were installed to handle the high heat load generated from:

• Offset printing machinery
• Drying sections
• Electrical panels
• Continuous manpower activity
• Solar heat transfer from sheet roofing

The units provide:

✔ Uniform air distribution
✔ High airflow performance
✔ Reliable cooling during peak summer conditions
✔ Better indoor comfort for operators and machine areas

Variable Speed Vertical Multistage Pump

A Variable Frequency Drive (VFD) operated Vertical Multistage Pump was incorporated to maintain constant pressure with variable flow operation.

Benefits Achieved:

• Energy-efficient system operation ⚡
• Automatic adjustment according to cooling demand
• Stable water circulation throughout the system
• Reduced electrical consumption during partial load conditions
• Smooth and reliable cooling performance

Benefits Achieved

After installation of the central cooling system, Printwell Offset experienced significant operational improvements:

✅ Improved Working Environment

The shop floor temperature was considerably reduced, creating a far more comfortable environment for machine operators and staff.

✅ Better Printing Consistency

Stable indoor conditions helped improve print quality consistency and reduced temperature-related production issues.

✅ Reduced Heat Stress

The cooling system effectively minimized the intense heat buildup caused by sheet metal roofing during summer months.

✅ Energy Savings

The variable speed pumping system optimized energy consumption based on actual cooling requirements.

✅ Reliable Industrial Performance

The system continues to deliver stable cooling even during continuous printing operations and peak summer temperatures.

Project Summary