TE Connectivity has improved cooling efficiency and reduced energy consumption at its Hastings site through a free cooling project delivered with ICS Cool Energy. The global manufacturer uses process cooling to support injection moulding operations, where stable temperatures are critical to maintaining machine performance and product quality. Having worked with ICS Cool Energy on temperature control for a number of years, TE Connectivity was looking for an opportunity to upgrade older equipment and introduce free cooling to improve efficiency and reduce operating costs. By installing a new system with free cooling capability, ICS Cool Energy helped TE Connectivity reduce chiller run-time, lower electricity consumption and improve reliability across a critical manufacturing process. The project has also given the business a strong platform for wider sustainability improvements, with the free cooling approach now being considered at other TE Connectivity sites. Challenge At TE Connectivity’s Hastings facility, process cooling plays an essential role in supporting injection moulding operations. Cooling is used to control temperatures around the moulding process, including heated tools, barrels and other critical machine components, helping to prevent overheating and maintain stable operating conditions. For a manufacturing process that depends on temperature stability, any loss of cooling performance creates operational risk. If temperatures rise too far, machines can alarm and stop, affecting production continuity and potentially product quality. As TE Connectivity looked to reduce energy use and improve environmental performance, the Hastings team wanted a more efficient solution that would not only improve reliability, but also use low ambient conditions to reduce mechanical cooling costs during cooler periods of the year. Solution Building on its existing relationship with the site, TE Connectivity approached ICS Cool Energy to upgrade the moulding process cooling system and integrate free cooling capability. temperatures required for injection moulding operations. The project has delivered both operational and energy-saving benefits for TE Connectivity. By installing new chillers with free cooling, the site has improved the reliability of a critical utility supporting its injection moulding process, while also reducing electricity consumption. “We’ve seen energy bills come down drastically, and the system has been running very well. Free cooling has been a major factor. The chillers are usually running at 60 to 80 kilowatts, while in winter, the free cooler is 28 | Plant & Works Engineering www.pwemag.co.uk October/November 2026 Energy & Environmental Management Focus on: Cooling Free cooling cuts energy demand in injection moulding The project included the installation of a set of run standby chillers, both able to work alongside the free cooler. This arrangement gives the site both resilience and flexibility, allowing units to be alternated to support servicing and routine maintenance. The free cooling system reduces reliance on compressor-driven mechanical cooling by using lower ambient temperatures to assist the process whenever conditions allow. At TE Connectivity, this has enabled the site to cut energy use significantly, particularly during cooler months, while maintaining the
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