280kW Air-Cooled Chiller Ensures Stable Cooling for a Stretch Film Production Line in Saudi Arabia's 48°C Climate
Project Background
An engineering contractor from Egypt contacted KANSA regarding a cooling project for a high-speed cast stretch film production line located in Saudi Arabia.
The chiller is mainly used for:
• Chill Roll Cooling
• 24-hour continuous operation
• High-speed cast film production
The project site is located near the Red Sea area, where summer ambient temperatures can reach 48°C with high humidity.
The customer's main concern was long-term stable operation under extreme weather conditions.
Customer's Existing System
The customer previously used an air-cooled screw chiller with the following configuration.
Existing Chiller
• Cooling Capacity: 220 kW
• Refrigerant: R134a
• Compressor: 1 × 80HP Semi-Hermetic Screw Compressor
• Chilled Water Flow: 35 m³/h
• Pipe Size: DN80 (4 inch)
• Design Ambient Temperature: ≤45°C
The customer informed us that:
• The project runs 24 hours continuously
• Summer ambient temperature can reach 48°C
• Humidity is high due to the Red Sea coastal environment
• Higher reliability is required
Engineering Challenges
Challenge 1
High Ambient Temperature
The original chiller was designed for:
≤45°C ambient temperature
However, the actual project environment reaches:
48°C+
This may cause:
• Condensing pressure increase
• Cooling capacity reduction
• Higher compressor load
• Reduced system reliability
Challenge 2
Single Compressor Design
The original design used:
1 × 80HP compressor
Customer preferred:
2 × 40HP
or
4-compressor configuration
Advantages:
• Better part-load efficiency
• Lower starting current
• Redundancy protection
• Easier maintenance
• Continued operation if one compressor fails
Challenge 3
Continuous Production
The stretch film production line operates:
24 hours per day
Continuous operation requires:
• Stable water temperature
• Reliable compressor operation
• Enhanced condenser capacity
• High-temperature protection
KANSA Solution
After reviewing the project conditions, KANSA engineers recommended:
Model
ICS-100A Air-Cooled Scroll Chiller
Technical Data:
• Cooling Capacity: 280 kW
• Power Supply: 380V / 3Ph / 60Hz
• Compressor Quantity: 3 Scroll Compressors
• Water Flow Rate: 48.2 m³/h
• Pipe Size: DN80
• Stainless Steel Shell & Tube Evaporator
• High-Efficiency Internal Thread Condenser
• Multiple Safety Protection Functions
Compared with the previous 220kW unit, the ICS-100A provides approximately 27% higher cooling capacity and better adaptability to high-temperature environments.
Why ICS-100A?
More Cooling Capacity
220 kW → 280 kW
Additional capacity helps compensate for cooling loss under 48°C ambient temperature.
Multi-Compressor Design
The ICS-100A adopts:
4 Scroll Compressors
Benefits:
• Better load matching
• Improved reliability
• Reduced downtime risk
• Easier maintenance
Designed for Industrial Continuous Operation
Suitable for:
• Plastic extrusion lines
• Cast film lines
• Packaging film production
• 24-hour manufacturing environments
Expected Benefits
✔ Stable operation during Saudi summer
✔ Improved cooling performance for chill rolls
✔ Reduced risk of high-pressure shutdown
✔ Higher production stability
✔ Better compressor redundancy
✔ Lower maintenance risk
Project Result
After technical discussions regarding:
Ambient temperature
01
Humidity
02
Compressor configuration
03
Refrigerant selection
04
Continuous operation requirements
05
Applications
• Cast Film Production Line
• Stretch Film Production
• Blown Film Production
• Plastic Sheet Extrusion
• Plastic Packaging Industry
• Industrial Cooling Systems
For customized cooling solutions for plastic processing projects, KANSA provides complete support from equipment selection to engineering design.
