The Challenge: Rising to Customers’ Exacting Standards

In an industry driven by high-performance demands, Cormack Packaging

must continuously advance speed, precision and effi ciency for its high-

profi le clients. Already leveraging state-of-the-art molds and machines in

its operation, the company then turned its attention to another key factor

in high performance: its process cooling system.

At their Condell Park manufacturing facility, located in Sydney, Australia,

the company was using two process cooling systems to supply cooling

water to the plant: cooling towers and a central chilling system. The

system was creating several ineffi ciencies in the plant, including:

• Considerable water losses due to evaporation from cooling towers

• High costs of chemical treatment due to the risk of Legionella

• Inability to deliver different process water temperatures to the

entire plant

• Large pumping capacity required regardless of number of

machines in operation

Given the company’s competitive pressures, these problems were all

unacceptable. It was time for an upgrade.

The Solution: Reinventing the Process with Closed-Loop Cooling

To elevate its production for customers, Cormack turned to Frigel for its

reputation for process cooling expertise combined with a proven history

of water and energy savings as well as productivity improvements.

Cormack at a Glance• Manufacturer of packaging

closures for a variety of industries

• Based in Sydney, Australia with

offi ces in Melbourne and

Auckland, New Zealand

• Currently using a Frigel Ecodry

EDK72 unit and Microgels at its

Condell Park manufacturing facility

Propelling World-Class

Process PrecisionCPG Packaging Producer Elevates Its Game with Intelligent Cooling

CASE STUDY: Cormack Packaging

CASE STUDY: Cormack Packaging

www.frigel.com

Frigel’s team of process cooling experts set out to create

the best solution to help increase effi ciency for the plant.

Beginning with a full survey and technical analysis of

the plant, Frigel engineers helped Cormack discover

new options for process cooling, providing a step-by-

step approach to implementing new process cooling

technologies in their plant.

The plan included:

• A Frigel Ecodry EDK72 (14 fan) unit in place of the

plant’s cooling towers. The Ecodry adiabatic dry

cooling system takes warm process water from the

plant and passes it through a series of closed heat

exchangers, where the heat is drawn from water by

variable speed fans.

• Microgel combined chiller/temperature control

units –RCM60s, RCM100s and RCM201, 24 in total

– installed at each machine, replacing the old

centralized chiller.

• Using existing structures, including pipe work, to

save money on the upgrade.

The patented closed-loop adiabatic dry cooling eliminates

water evaporation for dramatic water savings compared

to the cooling towers, while the compact individual chillers

make production more precise and effi cient by allowing

a higher overall water temperature in the system and

enabling individual items of production to be switch off

when not needed.

In October 2012, with help from a funding grant from

the AusIndustry Clean Technology Investment Program,

Cormack Packaging installed the Frigel system into the

Condell plant.

The Result:Better Process Performance across Many Parameters

Frigel’s process cooling solution allowed Cormack

Packaging to increase production effi ciency and improve

environmental sustainability in the Condell plant.

The new installation helped Cormack:

• Decrease water loss due to evaporation associated

with traditional cooling towers.

• Eliminate the risk of Legionella bacteria due to the

closed-loop nature of the system.

• Reduce chemical consumption.

• Decrease the plant’s energy consumption.

• Increase system quality and uptime due to

consistent, precise water temperature control.

“ The new Ecodry and Microgel units from Frigel have allowed us to dramatically improve production by increasing effi ciencies in our entire system. By providing greater fl exibility in operating our process cooling systems, we’ve greatly increased our energy savings and productivity in our process.”

Dave Armstrong,

Technical Manager at Cormack Packaging.