Ductline / Pre-Insulated Ductworks

The Challenge

A prominent manufacturer of pre-insulated duct systems, located in Dubai Investment Park (DIP), faced operational limitations caused by inadequate cooling during duct production. The process requires injecting 20mm polyurethane foam between two aluminium foils – a task that demands precise temperature control to ensure consistent quality and performance.

Industry: Metal Works
Application: Precision cooling for conveyor belt during PU foam injection

Previously, the production line relied solely on ambient fresh air for cooling. This approach proved insufficient, particularly during Dubai’s extreme summer months. Recognising the need for a dedicated cooling system, the customer sought a solution but lacked clarity on the required cooling capacity.

Challenges
  • Undefined Cooling Requirements: No prior data was available on the actual cooling load.
  • Inefficient Existing Setup: Reliance on fresh air cooling led to product inconsistencies and production delays.
  • Site-Specific Complexity: Multiple inspection visits were necessary to understand layout, process flow, and thermal demands.
Considerations for the Replacement Plan
  • Data-Driven Sizing: Accurate load calculation and OEM validation were essential for proper system design.
  • Production Efficiency: Stable cooling was needed to maintain belt temperature and optimise foam injection.
  • Seasonal Load Variability: The system had to perform reliably even during peak summer conditions.
  • Long-Term Reliability: An energy-efficient solution was required to minimise downtime and ensure operational stability.

The Solution

Following a comprehensive site assessment and collaboration with the OEM supplier, we delivered a tailored cooling system designed to meet the specific demands of the duct manufacturing process.

Proposed Solution
  • 1 Unit of MTA TAEevoTech 351 Air-Cooled Process Chiller
  • Cooling Capacity: 70 kW
Key Advantages of Choosing MTA
  • Precision Cooling: Maintains conveyor belt temperature at 35°C, ensuring injection consistency.
  • Optimised Production: Stable cooling improved output and reduced foam waste.
  • Efficient System Design: Engineered for reliable performance in Dubai’s high ambient conditions.
  • Reliable Operation: Energy-efficient with low maintenance requirements.
  • Service Continuity: Supported by a signed Annual Maintenance Contract (AMC) for long-term reliability.
  • Strong Local Support: Fast response times and on-site expertise ensured seamless installation and commissioning.

The Result

  • Successful System Delivery
    Cooling capacity was accurately calculated, validated with the OEM, and a 70 kW MTA chiller was commissioned successfully.
  • Production Gains
    Improved temperature regulation accelerated production cycles and reduced material waste.
  • Product Quality Boost
    Consistent process cooling delivered higher-quality duct panels.
  • Ongoing Partnership
    A signed AMC guarantees preventive maintenance and operational stability.
  • Customer Satisfaction
    MTA Dubai provided a customised, reliable solution, earning the client’s trust for future projects.