We design and engineer custom solutions for all types of equipment, including:

• Chiller units – air-cooled or water-cooled, configurable for any temperature range

• Adiabatic cooling systems – high-efficiency alternatives to cooling towers with reduced water usage

• Pump skids – complete with pumps, controls, valves and instrumentation

• Heat exchanger packages – plate, shell & tube, brazed, or specialist materials

• Filtration systems – to protect equipment and maintain water quality

• Glycol systems & low-temperature packages

• Heating and Cooling built specifically for unique processes

Whether your solution requires a carefully selected off-the-shelf product or a completely bespoke manufacturing design, we ensure it is engineered to deliver:

• Optimal cooling capacity

• Energy-efficient operation

• Long-term reliability

• Seamless integration into your process

• Low total cost of ownership

• Flexibility for future expansion

By working with multiple manufacturers, not being tied to a single supplier, we can combine the best technologies to create the ideal system layout for your site. Every design can be supported with detailed engineering documentation, process analysis and optional 3D system modelling for complete clarity before installation.

• Our turnkey services include:

  • Civil Works (Civils)

  We manage all groundworks, bases, plinths, concrete pads and builder’s work required for equipment installation.

  • Offloading, Positioning & Heavy Lifting

  We safely offload and move equipment into place, using cranes, forklifts or specialist lifting equipment, ensuring correct positioning with full risk assessment.

  • Removal of Old Equipment

  We decommission and remove redundant or outdated cooling systems, including pipework, electrical supplies, tanks, and associated plant.

  • Skid-Mounted System Options

  To minimise on-site disruption and improve health & safety, we can design and build skid-mounted cooling packages that arrive pre-assembled and pre-tested.
  This reduces installation time, simplifies logistics, and limits hot works and high-risk activities on your site.

  • Factory Acceptance Testing (FAT)

  Conducted prior to delivery, FAT ensures your equipment is fully tested, configured and compliant before it leaves the manufacturer.

  • Site Acceptance Testing (SAT)

  Once installed, we perform site acceptance tests to verify performance, safety and integration with your plant.

  • System Filling & Chemical Treatment

  We fill and pressurise the new system, including water treatment, filtration and glycol where required.

  • 3D Modelling Prior to Build

  To eliminate installation issues, we offer 3D model visualisations that show equipment placement, pipe routes, access zones and plantroom layout before work begins.

• Full CDM Compliance

  We can take full responsibility for CDM (Construction Design & Management) Regulations where required.
  This includes:

  • Principal contractor role

  • Health & safety planning

  • RAMS documentation

  • Site coordination

  • Contractor management

  • Compliance with legal obligations

  This ensures your project meets all safety and construction standards from start to finish.

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  Why Customers Choose Our Turnkey Installation Service

  • Managed by a dedicated project manager

  • Reduced downtime & disruption

  • Safer installation with skid-mounted options

  • Full mechanical, electrical & civils capability

  • Seamless removal of old equipment

  • Full testing: FAT & SAT

  • 3D models for total design clarity

  • Complete CDM compliance available

  • UK-wide installation coverage

   

Why Proper Commissioning Matters

Many system issues; high running costs, unstable temperatures, poor control response, noise, pump problems, or early equipment failure, can be traced back to inadequate or incomplete commissioning.

Correct commissioning ensures:

• The system performs to the original design intent

• Energy efficiency is maximised from day one

• Correct flow, pressure and temperature profiles

• Refrigeration circuits operate within safe limits

• Pumps, valves and controls are correctly balanced

• Alarms and safety interlocks function properly

• Chillers respond correctly to load changes

• The system is stable, safe and reliable

Commissioning isn’t a box-ticking exercise, it’s a highly technical process that determines how well your cooling plant will run for the next 10–15 years.

Our Design Team is On Site for Final Commissioning

To guarantee the system performs exactly as engineered, our design team also attends site during final commissioning.

This ensures:

• The installed system matches the design

• Control logic is set correctly

• Flow and pressure values are confirmed

• Pump sets and pipe circuits are optimised

• Temperature targets and safety bands align with design parameters

• Any final adjustments enhance long-term efficiency

This dual-approach, commissioning engineers + design engineers, ensures your equipment is handed over in perfect working condition.

What Our Commissioning Service Includes

Our full commissioning process covers:

• System flushing & cleaning

• Refrigeration performance checks

• Pump balancing & flow verification

• Temperature calibration

• BMS and control strategy configuration

• Alarm and safety device testing

• Electrical and mechanical verification

• Load testing where possible

• Final system optimisation

• Comprehensive commissioning report

We do not leave site until the system is running reliably, efficiently, and exactly in line with the intended design.

Why Choose Process Cooling for Commissioning?

• Four trusted UK commissioning partners

• High-level engineering expertise

• Design team attendance for final commissioning

• Detailed documentation and reporting

• Focus on efficiency, reliability and performance

• Experience across all major industrial sectors

• Commitment to long-term system success

• A Strategy-Driven Approach to Maintenance

  Every maintenance contract includes a structured forward-planning strategy, giving you a clear roadmap for the next: 1 year, 3 years, 5 year 10 years

  This long-term plan forecasts:

  • Expected component lifecycles

  • Recommended upgrades or replacements

  • Energy-efficiency improvement opportunities

  • End-of-life planning

  • Budget forecasting

  • Risk reduction & downtime mitigation

  • Reliability-centred maintenance priorities

  We present this strategy to you in a professional PowerPoint presentation, which your management team can easily review, share, and integrate into internal planning.

  This makes our maintenance contracts an essential part of business continuity planning, not just equipment servicing.

  Proactive Remote Monitoring (Where Possible)

  Where systems allow, we strongly encourage the use of remote monitoring. This helps identify issues before they become failures and allows us to offer a highly proactive service.

  Remote monitoring benefits include:

  • Early detection of performance drops

  • Alerts for temperature, pressure or flow deviations

  • Predictive maintenance capability

  • Reduced downtime & emergency callouts

  • Better energy performance insights

  • Data-driven optimisation recommendations

  Remote monitoring provides a deeper understanding of how your cooling system performs day-to-day, giving you confidence in both reliability and efficiency.

Traditional Maintenance — Carried Out to the Highest Standards

Alongside strategy and monitoring, our engineers still perform comprehensive hands-on maintenance on all cooling equipment, including:

• Chillers

• Adiabatic coolers

• Dry coolers

• Pump sets

• Heat exchangers

• Controls & sensors

• Water treatment

• Filtration systems

• Third-party equipment

Every visit includes full system checks, performance testing, safety validation and clear service reports.

The Benefits of Our Maintenance Contracts

• Improved reliability and reduced downtime

• Lower operating and energy costs

• Longer equipment lifespan

• Clear long-term planning & budgeting

• Transparent asset management

• Early fault detection and prevention

• Priority response for contract customers

• Support for all equipment brands and manufacturers

Why Water Treatment Is Essential

Cooling systems without proper treatment often experience:

• Scale on heat exchangers (reducing efficiency)

• Corrosion inside pipework and chillers

• Biofilm and bacteria formation

• Blockages in strainers, pumps and valves

• Increased energy consumption

• Unstable system flow rates

• Higher maintenance costs

• Shortened equipment life

Even the most advanced cooling system will underperform if the water inside it isn’t correctly managed.

Our Water Treatment Services Include

• Chemical Dosing & Inhibitors

We supply and dose high-quality corrosion inhibitors, scale protectors and biocides specifically designed for cooling system conditions.

• Closed-Loop Protection

We protect your closed-loop chilled water network from corrosion, fouling and microbiological growth — essential for long-term reliability.

• System Cleaning & Flushing

We remove contaminants, sludge and scale from existing systems and restore design performance, perfect before upgrades or plant changes.

• Water Sampling & Laboratory Analysis

We take onsite samples and provide full lab reports, giving you a clear picture of system health and highlighting corrective actions.

• Glycol Supply, Testing & Freeze Protection

We specialise in glycol systems, ensuring correct concentration, cleanliness, compatibility and freeze-point protection.

• Filtration & Side-Stream Filters

We supply and install filtration systems to continuously clean the water as the plant runs.

• Adiabatic Cooler Water Treatment

We protect adiabatic systems from scale, bacteria and drift issues — essential for performance and compliance.

• Microbiological Control

We identify and treat bacteria growth, biofilm formation and conditions that lead to contamination.

Why Good Water Treatment Saves You Money

Poor water quality can reduce cooling efficiency by 10–30%, significantly increasing your energy bill.
By maintaining clean, stable water chemistry, you benefit from:

• Lower energy consumption

• Extended equipment lifespan

• Reduced maintenance visits

• Fewer breakdowns

• Improved heat transfer

• Stable system flow and pressure

• Safer overall operation

Well-treated water ensures your cooling system operates as efficiently as it was designed to.

Integration With Maintenance Contracts

Water treatment can be included as part of our long-term maintenance strategy, ensuring:

• Regular sampling

• Updated test certificates

• Accurate chemical dosing

• Long-term corrosion monitoring

• Predictive maintenance insights

• Compliance with environmental standards

This aligns with your 1-3-5-10 year cooling roadmap and supports Net Zero goals through improved efficiency.

Why Choose Process Cooling for Water Treatment?

• Specialist knowledge of cooling system chemistry

• Reliable, high-performance treatment products

• Full support for glycol and low-temperature systems

• Independent advice — not tied to one supplier

• Full sampling, testing and reporting

• Integrated service with maintenance contracts

• Focus on efficiency, reliability and long-term protection

Hire Solutions for Every Requirement

Because we partner with multiple national hire providers, we can arrange:

• Short-term hire

• Long-term hire (including multi-year agreements — 5 years and beyond)

• Emergency same-day hire

• High-capacity MW-scale cooling solutions

• Small, single-unit hire options (such as pumps or small chillers)

No requirement is too big or too small — from supplying a single pump to an entire MW-level temporary cooling plant, we have the connections and knowledge to deliver the right solution.

Types of Equipment We Can Arrange for You

Our hire partners can provide a full range of temporary equipment, including:

• Process chillers

• Air-cooled and water-cooled chillers

• Pump skids and standalone pumps

• Air handling units (AHUs)

• Heat exchangers

• Dry coolers & adiabatic units

• Boilers & temporary heating systems

• Space heating & building heating systems

• Temporary space cooling for comfort

• Hose packages, manifolds & accessories

Whether your business needs fast temporary cooling or large-scale heating support, we ensure the equipment is reliable, efficient and correctly sized for your requirements.

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Why Work With Us for Hire?

• Access to multiple specialist hire companies

• Independent, unbiased guidance

• Fast turnaround during emergencies

• Any scale: from single pumps to MW cooling

• Temporary cooling and temporary heating solutions

• Long-term and short-term hire options

• Reliable, efficient and correctly sized equipment

• What our load calculations include

  • Detailed assessment of your process and equipment

  • Heat rejection analysis

  • Flow and pressure requirements

  • Ambient operating profiles (summer/winter)

  • Diversity and peak demand analysis

  • Redundancy planning (N+1 / duty-standby)

  • Future-proofing for production changes

  • Comparison against your existing equipment’s performance

  By understanding your true load, we help prevent premature chiller breakdowns, oversized systems, energy waste, and costly mistakes during replacement.

Why this matters for your business

A correctly sized system offers:

• Lower operating costs

• Longer equipment life

• Stable, reliable temperature control

• Fewer breakdowns

• Better long-term asset planning

• Improved production efficiency

Investing in process cooling equipment is a long-term decision — and we ensure it’s based on accurate data, not assumptions.

Why accurate load calculation is essential

When you’re investing in new process cooling plant, knowing your actual thermal load is absolutely critical. It ensures:

• The equipment is matched to the real process demand

• Energy consumption is minimised

• Reliability and system longevity are improved

• Future expansion and growth are factored into the design

• Capital investment is spent in the right place

• Operating costs remain under control

At Process Cooling, we specialise in carrying out detailed process load calculations to establish your true cooling demand before any equipment is selected.

What we deliver

Its more than just a schematic we will check the system design and make recommendations of improvements, if required. Our engineers produce comprehensive schematic drawings that detail:

• Flow and return pipework routes

• Pumps, valves and control sequences

• Heat exchangers, chillers, coolers and ancillary equipment

• Sensors, gauges and monitoring points

• Safety devices and isolation points

• System flow direction and operational logic

• Any legacy changes or undocumented modifications

These drawings give your team a complete understanding of the system layout, helping to ensure safe operation and faster decision-making.

When to update your schematics

We recommend producing or refreshing system drawings when:

• Equipment has been replaced

• Pipework has been altered

• A new extension or production line has been added

• You experience a breakdown that reveals gaps in system knowledge

• Your maintenance strategy is being reviewed

• You are preparing for system upgrades or expansions

Clear Guidance Based on Your Actual System Design

Every checklist we create is based on your actual cooling system layout, design intent and performance parameters. This includes:

• Key operating conditions (temperatures, flows, pressures)

• Allowable safety bands and alarm thresholds

• Daily and weekly operational checks

• Maintenance intervals and tasks

• Critical components that require regular inspection

• Start-up and shutdown procedures

• Escalation steps if system readings fall outside design limits

This ensures your team always knows exactly what “good” looks like — and what to do when something isn’t right.

All Documentation Stored and Organised for Your Service Team

In addition to checklists, we compile a full documentation pack that may include:

• Design reports

• Commissioning data

• P&IDs / schematic drawings

• Manuals & OEM documentation

• Maintenance instructions

• Control strategy explanations

• Safety and compliance records

This ensures your service team has instant access to all relevant information, enabling them to maintain your system correctly, diagnose issues faster and prevent errors caused by missing or outdated paperwork.

Why this matters for your business

Clear operation procedures and documentation help you:

• Maintain stable and efficient cooling system performance

• Reduce breakdowns caused by incorrect operation

• Improve safety for engineers and operators

• Avoid costly mistakes during maintenance

• Ensure compliance with internal and external standards

• Reduce energy waste and protect equipment life

A well-documented system is a reliable system.