Case Background: Challenges of the Cooling Water System in a Large Automobile Parts Manufacturing Plant in Southeast Asia
Client: The Malaysian factory of a well-known automobile parts manufacturing group
Industry: Automobile manufacturing
Challenges: The central cooling tower system of this factory, which is equipped with multiple injection molding and die-casting production lines, has long been facing issues with the quality of the circulating water. The cooling water contains metal debris, plastic particles, algae, and pipe rust residues, causing frequent blockages of the plate heat exchangers and a reduction in heat exchange efficiency by over 30%. Monthly shutdowns are required for manual chemical cleaning and disassembly and rinsing, which not only incurs high maintenance costs and chemical agent expenses, but more seriously, the unexpected shutdowns lead to production interruptions, with an average loss of approximately 40 hours of effective production time per month. The client has previously attempted to install traditional basket filters, but they required frequent manual cleaning, with poor results and high labor intensity.
Our solution: Fully automatic brush-type self-cleaning filtration system
After our engineers conducted on-site inspections and analyzed the water quality, we customized and installed a “PLC intelligent control brush-type self-cleaning filter” for the customer as a secondary filtration system for the cooling tower.
Precise selection: Based on its total circulation water volume, we recommended and installed a model with a flow rate of 100 m³/h. It uses a 50-micron precision SS304 wedge-shaped filter screen, which is sufficient to intercept the key particles that cause blockage.
Intelligent operation: The equipment is connected to the customer’s central control room. The filter monitors the cleanliness of the filter screen in real time through a differential pressure sensor (with a set value of 0.15 MPa). When the differential pressure reaches the set value, the PLC automatically initiates the cleaning procedure: the motor drives the nylon brush to rotate, thoroughly cleaning the inner wall of the filter screen, while the DN50 electric discharge valve opens for approximately 15 seconds, quickly discharging the impurities from the system. The entire process is completed within 20 seconds, and the system maintains uninterrupted water supply.
Sturdy and durable: The Q345 carbon steel shell and the fully stainless steel internal components are adapted to the factory environment; the nitrile rubber seal ensures long-term leak-free operation.
Implementation outcomes and customer benefits
Since the equipment was installed and put into operation six months ago, it has brought immediate and sustained benefits to the customers:
Completely eliminate blockages and enhance production efficiency: The plate heat exchanger has never experienced efficiency decline or shutdown due to blockages. The temperature difference of the cooling system remains stable at the designed value, ensuring constant temperature production conditions for injection molding machines and die-casting machines. Production interruption losses have been reduced to zero.
Significantly reduce operating and maintenance costs:Reduce maintenance costs: Elimination of monthly manual chemical cleaning and filter disassembly cleaning results in an estimated annual savings of approximately $18,000 in maintenance expenses.
Water and energy conservation: The automatic cleaning process uses extremely low water consumption each time. Compared to traditional reverse osmosis filters, water savings exceed 60%. The improvement in system efficiency also leads to indirect energy savings for the cooling water pump.
Extending the lifespan of the main equipment: Clean circulating water significantly reduces corrosion and scaling of heat exchangers, pumps, valves and pipelines, thereby extending the service life of the entire cooling system assets.
Intelligent management, achieving unmanned operation: Operators can view the running status and pressure difference history at any time through the large LCD display. The fault warning function alerts of any abnormalities in advance, transforming maintenance work from “emergency repair” to “planned maintenance”, making management more effortless and efficient.
Reliable cooperation experience: Our fast delivery time has ensured the progress of the project. The equipment operates without faults within the one-year warranty period. Customers highly appreciate the rapid response of our after-sales team. The professional training provided during the installation and commissioning stage ensured that the factory staff could operate proficiently.
Customer Testimonial
“This automatic filter is one of the most successful environmental improvement investments we’ve made this year. It is not just a filtration device; it is also a crucial part of our strategy to ensure continuous production. Since its installation, we no longer have to worry about the cooling water issue, truly achieving ‘set and forget’. The professional solution and reliable product from the supplier have left a deep impression on us.” —— Customer’s Factory Equipment Department Manager
Post time: Jan-06-2026