Focus on: Process Cooling Process, Controls & Plant Annual Buyers’ Guide 2026 www.pwemag.co.uk Plant & Works Engineering | 27 product portfolio but decades of expertise in process cooling,” says Ferriday. “Combining that with our heritage in compressed air has created a much broader ecosystem. We can now deliver integrated solutions across cooling, air, and gas, supported by shared service infrastructure and R&D.” One of the main benefits has been in controls and connectivity. “The Elektronikon Mk5 controller used across our compressors is now standard on our chillers too, giving users the same intuitive interface and SMARTLINK connectivity. This consistency means customers can monitor both compressed air and cooling assets on the same platform, with shared diagnostic and performance data. It’s a simple but powerful advantage; especially for sites running mixed utilities where downtime in one area can affect the whole production chain.” Integration has also widened Atlas Copco’s reach into new markets. “Eurochiller was traditionally strongest in plastics, but Atlas Copco’s reach has opened up new opportunities in sectors such as food and beverage, pharmaceuticals and general manufacturing,” Ferriday says. “The product portfolio has expanded accordingly - the TCS range now covers 110 kW to 610 kW and will be further complemented with larger models in the future.” The TCS range, he adds, demonstrates the value of combining design philosophies. “It’s modular, compact and engineered to deliver SEPR values consistently above 6, outperforming many competitors. Every element, from heat exchangers to control logic, reflects Atlas Copco’s engineering DNA, while the refrigerant and configuration options build on Eurochiller’s process know-how.” The move towards low-GWP refrigerants The F-Gas phase-down continues to reduce the availability of high-GWP refrigerants, making low-GWP alternatives such as R454B increasingly relevant. “R454B delivers comparable cooling capacity to R410A but with nearly 80% lower Global Warming Potential,” Ferriday says. “It performs very efficiently under partial loads, which supports higher SEPR values, and it’s well suited to industrial environments where stable performance and compliance are equally important.” Transitioning to refrigerants with mild flammability ratings has required some adjustments. “The A2L classification means we’ve had to update safety protocols and training for service engineers - covering leak detection, handling procedures and risk assessment,” he explains. “In practice, R454B’s flammability is extremely mild and well within safe parameters, but awareness and education are essential.” The company has introduced training and documentation to ensure safe and consistent practices. “We’ve provided comprehensive training and documentation for our teams and partners to ensure consistent standards across the field. The transition has been smooth, and the environmental benefits far outweigh the additional precautions.” Ferriday notes that many customers begin by focusing on compliance but soon recognise the operational benefits. “Initially, compliance tends to be the primary driver: no one wants to be caught out by changing regulations. But once customers understand the stability and efficiency benefits, they increasingly view low-GWP refrigerants as a strategic investment.” While R454B is part of a wider trend towards lower-impact systems, Ferriday sees it as a long-term option rather than a short-term measure. “Every refrigerant is part of a transition towards lower impact, but R454B is a very solid long-term solution. It offers low GWP, high efficiency and compliance longevity; so customers investing today can do so with confidence that their equipment will remain future-proof for many years.” Connectivity, monitoring and predictive service Connectivity is now integral to industrial equipment. “Connectivity is becoming the new standard,” says Ferriday. “With the Elektronikon Mk5 controller and SMARTLINK portal even smaller chillers under 150 kW can now provide real-time insights on performance, alarms and energy use.” This level of monitoring has practical advantages. “Simple temperature or pressure deviations can reveal a lot. For example, a compressor once sent a high-temperature warning that traced back to a delivery van blocking the ventilation intake - something easily missed without monitoring. By acting early, the customer avoided production loss worth thousands.” The same approach is being applied to chillers. “By continuously monitoring parameters such as water temperature, refrigerant pressure and compressor load, we can identify early signs of imbalance or wear long before they cause a breakdown. It’s the difference between waiting for a fault and understanding when attention is due - much like maintaining a car based on how it’s actually driven rather than just relying on an MOT or annual service to fix issues.” These insights are enabling a move from fixed-interval maintenance to data-led servicing. “It means maintenance can become genuinely proactive: engineers visit only when there’s a need, equipment runs more efficiently between services, and customers gain greater uptime with lower total cost of ownership.” Looking further ahead, Ferriday sees the role of artificial intelligence increasing. “AI and machine learning will make it easier to interpret the vast amount of data these systems generate. Rather than manually analysing trends, AI can recognise subtle patterns - such as pressure fluctuations or temperature drifts - and predict likely issues. Over time, we envisage systems being able to learn the operating profile of each site and make recommendations automatically. It’s about turning data into foresight: identifying not just when maintenance is needed, but how to optimise performance continuously.” As environmental expectations continue to evolve, process cooling design is being shaped by a combination of regulation, efficiency, and digital capability. For Ferriday, the direction of travel is clear: “Our guiding principle of ‘there’s always a better way’ means we treat compliance as a catalyst for innovation rather than an obstacle. The goal remains the same: to provide cooling solutions that meet industrial performance needs while being as kind to the planet as possible.”
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