£625K Saving on Chiller System Capital

A 500-employee manufacturing site, part of a £21 billion global corporation, was facing a major capital investment. A third-party consultant had advised immediate replacement of an aging Chiller System, citing environmental risk and reliability concerns. The proposed solution came with a £600,000 price tag.

Before committing to this significant expenditure, the client engaged Projective to provide an independent technical review. The goal was to validate the system’s condition, assess actual cooling requirements and explore smarter, lower-cost alternatives that would maintain performance and reduce risk.

Projective began with a rapid technical review using our Intelligent Engineering System (IES). Instead of defaulting to asset replacement, we assessed how the Chiller System performed within the wider production process, revealing inefficiencies and overcapacity.

By optimising the system as a whole, we enabled safe decommissioning of aging assets without environmental risk or operational disruption.

Key focus areas included:

• Cooling load analysis to match system output with actual demand
• Identification of energy and water inefficiencies
• System-wide performance optimisation
• Safe decommissioning of aging assets

Projective’s engineers applied their Intelligent Engineering System (IES) to assess the Chiller System in a full operational context. Rather than replacing ageing assets, Projective focused on optimising performance across the entire system, delivering a smarter, lower-cost solution.

By identifying and eliminating inefficiencies, we enabled the safe decommissioning of equipment without environmental impact or production risk. The result was a £600,000 capital expenditure avoided, alongside £25,000 in annual savings through improved energy and water efficiency.

Projective’s independent, engineering-led approach ensured the client received a solution based on need, not product, unlocking long-term value and freeing up capital for growth.

This project highlights the value of engineering-led decision-making in complex industrial environments. By focusing on actual process needs rather than defaulting to asset replacement, Projective helped the client avoid unnecessary spend, reduce environmental risk and unlock long-term operational savings.

It’s a clear example of how our independent, system-focused approach delivers smarter outcomes, freeing up capital for growth, improving sustainability and building trust through results.