Client Overview

The solution was implemented in machine tool manufacturing environments where coolant chillers operate under conditions involving metal chips and process-related contamination.In machining operations, chips inevitably enter coolant tanks, even when filtration systems are in place. As a result, coolant entering chiller units may contain residual contamination, creating the need for a durable, serviceable cooling system capable of maintaining reliability while minimizing downtime and maintenance effort.

Challenges Faced

1. Coolant Contamination from Machining Processes

Machine tool operations generate metal chips and a portion of these chips inevitably enters the coolant system, even after filtration. This contamination can affect heat exchanger performance and overall chiller reliability.

2. Non-Serviceable Heat Exchangers in Conventional Chillers

Many competing chiller designs use narrow coolant flow paths within heat exchangers. When chips enter these systems, the heat exchangers become blocked and cannot be cleaned, requiring full replacement.

3. Time-Intensive Replacement and Downtime

Replacing a blocked heat exchanger requires:

• Cutting it out of the refrigeration circuit
  
• Installing a new unit
  
• Performing vacuuming and refrigerant gas recharging

This process typically takes two to three days, leading to extended downtime and increased recurring maintenance costs.

4. Frequent Failures in Highly Contamination-Prone Conditions

In machining operations where chip load and contamination are common, conventional heat exchangers tend to fail over time, increasing replacement frequency and service disruptions.

Solution by Lex Technoaid

Lex Technoaid developed coolant chillers with in-house designed shell-and-tube heat exchangers, engineered specifically for machine tool applications operating in highly contamination-prone conditions.

1. Removable and Cleanable Heat Exchanger Design

The heat exchanger is designed so that the entire unit can be removed, opened and cleaned, instead of being discarded. This eliminates the need to cut into refrigeration lines during maintenance.

2. Quick and Simple Cleaning Process

Cleaning requires loosening four to five bolts and an O-ring flange, allowing the unit cover to be removed, the heat exchanger to be cleaned thoroughly and reassembled.
The cleaning process typically takes 30 minutes to one hour.

3. Designed to Handle Residual Chip Contamination

The chiller is built to operate reliably even when coolant contains residual chips, reducing the risk of blockage or premature failure when inlet filtration is not optimal.

4. Long-Term Serviceability and Reliability

Many customers have used these heat exchangers for more than ten years without replacing major components, with only occasional cleaning required. Lex Technoaid recommends cleaning once every six months to one year.

Outcome

1. Reduced Maintenance Downtime

Customers avoided multi-day maintenance stoppages, with servicing completed in under one hour instead of two to three days.

2. Lower Long-Term Maintenance and Replacement Costs

By eliminating the need to replace heat exchangers and recharge refrigerant circuits, customers significantly reduced recurring maintenance expenses.

3. Improved Equipment Uptime

The simplified service process enabled continuous and reliable chiller operation with minimal production interruption.

4. Sustained Performance in Highly Contamination-Prone Machining Environments

The chiller design has proven effective in real-world machining operations where coolant contamination is unavoidable, maintaining stable cooling performance over long operational periods.