Since 1982 – Reliability in Every Batch
Case Study: Changeout of a PVC Cooling Mixer Compared to the Original Unit
Background
A mid-sized plastic processing plant specializing in a rigid PVC application experienced recurring downtime and inconsistent cooling performance with its original units. The Horizontal Coolers were not keeping pace with the Mixer and creating a bottle neck. One of the units had premature wear and was leaking water internally after 7 years of production requiring patching.
Original Cooling Mixer
- Manufactured by: Italian design
- Cooling capacity: 5,500L
- Cooling jacket design: Low Pressure Jacket with individual cooling zones
- Issues observed:
- Inconsistent cooling cycles leading to longer Blend Tower runtimes
- Frequent scaling inside the cooling jacket due to low pressure
- No local support
- Long lead times on parts
Motivation for Changeout
- Production losses due to long Cooling Times.
- Rising maintenance costs
- Demand for higher throughput
- Desire for faster parts delivery
New PVC Cooling Mixer (Installed Unit)
- Manufactured By: Reliance Industries, Inc.
- Cooling capacity: 5,500L
- Cooling jacket design: High Pressure jacket with Turbulent flow and 1 zone
- Key features:
- High pressure jacket allowing for a lower Delta T across the channel
- Reduced scaling and fouling
- Increased Throughput
. Changeout Process
- Preparation: Installation crew removed existing units and replaced with Reliance units. Both were replaced at the same time.
- Installation: New PVC cooling mixer installed and aligned in 3 days.
- Integration: Connected to existing control system with minor programming adjustments.
Results and Performance Comparison
| Metric | Original Cooling Mixer | New PVC Cooling Mixer |
|---|---|---|
| Throughput capacity | 6–7 batches/hr | 9–10 batches/hr |
| Batch consistency | ±10 °F Delta T | ±3 °F Delta T |
Benefits Achieved
- Production increase: ~42% more throughput
- Support: Support in same time zone and parts delivery within 24 hours as opposed to in Europe with parts deliveries taking weeks.
- Longevity: The original units had Inside Cylinders measuring 6mm upon start. Reliance units measure 12.7mm upon startup.
Conclusion
The changeout from the original cooling mixer to a Reliance cooling mixer provided substantial improvements in efficiency, reliability, and cost savings. Thicker walls equal longer life. Higher Pressure design equals more water flow which creates faster cooling rates. For facilities facing similar challenges, a modern PVC cooling mixer can be a strategic upgrade that enhances product consistency and reduces operational costs.
