Integrated cooling and heat recovery for industrial production
Project overview
Industrial production environments place complex demands on cooling systems. In light metal foundries, cooling must support stable process conditions while operating continuously and efficiently under high thermal loads.
For a light metal foundry in Germany, JAEGGI was selected to deliver a combined cooling and heating solution that would support reliable production while enabling effective reuse of waste heat generated during the process.
The challenge
The foundry required a system capable of:
- Maintaining stable process temperatures under continuous operation
- Managing high and variable thermal loads
- Enabling recovery and reuse of waste heat
- Integrating efficiently into existing production infrastructure
Light metal foundries operate under continuous production conditions with high and variable thermal loads. Cooling systems must maintain stable process temperatures at all times, with minimal tolerance for downtime or performance fluctuation.
In this case, cooling and heat generation were previously treated as separate systems. Cold production was energy-intensive, while valuable thermal energy from flue gases was not being recovered and reused. This separation limited overall energy efficiency and increased operating costs.
The foundry sought to improve energy utilization by recovering waste heat from the production process, without compromising cooling reliability or disrupting existing operations. Integrating heat recovery into an active industrial environment introduced additional complexity, requiring careful coordination between cooling performance, heat reuse, and long-term system stability.
The core challenge was to move from isolated cold and heat production toward a single, integrated system that could support process stability, enable effective energy reuse, and operate reliably over the full lifecycle of the facility.
The JAEGGI solution
JAEGGI implemented a combined cooling and heating system specifically designed for continuous foundry operation, where thermal stability and energy efficiency must be maintained in parallel.
The solution integrates JAEGGI cooling technology with Güntner heat exchangers and condensers, enabling coordinated heat rejection and heat recovery within a single system architecture. Waste heat generated during cooling and from flue gas processes is captured and reused within the facility, reducing overall energy demand while maintaining precise thermal control for production processes.
System configuration and operating modes were selected to manage high and variable thermal loads typical of light metal foundries. This ensures predictable performance across changing production conditions, while avoiding disruption to existing operations.
By combining cooling and heat recovery into a unified system, JAEGGI enabled the foundry to move away from energy-intensive, isolated cold production toward a more efficient, integrated approach, improving overall energy utilization without compromising process reliability or uptime.
Operational benefits
The installed solution supports:
- Stable thermal conditions for industrial processes
- Efficient reuse of waste heat within the facility
- Reduced overall energy consumption
- Reliable operation under continuous production loads
This integrated approach improves energy efficiency while supporting consistent, long-term system performance.
Outcome
The foundry transitioned from separate cooling and heat generation systems to an integrated thermal infrastructure that stabilizes production temperatures while recovering and reusing waste heat. Cooling and heating are delivered through a single coordinated system, reducing reliance on energy-intensive compression cooling. Dry operation covers the majority of annual operating hours, with adiabatic support required only during peak conditions (approximately 395 hours per year), limiting water use to those periods. The system supports continuous industrial production with improved overall energy utilization.
Project insight
A system-level approach enables industrial cooling infrastructure to support both process stability and effective energy reuse.