The original plan was to replace the aging chiller with another cooling-only unit. This would restore process-cooling capacity, but it would not solve the underlying energy problem. Useful heat would continue to be rejected outdoors, the boiler would remain responsible for the full sanitation hot-water load, and one large chiller could still create a single point of failure for production.

EXINDA reviewed the plant’s simultaneous cooling and hot-water requirements and identified an opportunity to connect the two loads. Heat removed from the production process could be recovered and transferred into the sanitation-water system instead of being wasted. The revised design therefore changed from a conventional chiller replacement to an integrated four-pipe heat pump solution providing process cooling and high-temperature hot-water production from one hydronic platform.

The proposed system uses four EXINDA 30 Ton R515B Water-Cooled Scroll Heat Pump Chillers in a 3+1 configuration. Three modules provide up to 90 Tons of normal operating cooling capacity, while the fourth supports peak demand, unit rotation or standby operation. Each unit delivers 30 Tons of cooling, up to 432,000 BTU/h of heating and hot water up to 180°F (82°C). The R515B A1 refrigerant, 575V/3Ph/60Hz power supply, four-pipe configuration, modular staging and BACnet/Modbus integration make the system suitable for continuous industrial operation and future expansion.

The EXINDA system produces 44°F (6.7°C) process chilled water while recovering available heat for sanitation-water preheating, with approximately 140°F (60°C) selected as the normal project target. The existing boiler remains available for final temperature lift, peak demand and emergency backup. Compared with a cooling-only replacement, the solution reduces rejected heat and boiler dependence while providing modular redundancy, better part-load matching, individual-unit serviceability and a practical path toward industrial electrification.