When it comes to discussions about replacing water cooling systems in process cooling applications, improving the bottom line isn’t usually the first topic on the agenda. Yet, for many UK factories, the opportunity to do just that is very real. And no, this isn’t another article telling you to install higher efficiency motors or add variable speed drives—though those are certainly worthwhile.
This is about taking a holistic approach to process cooling, examining the entire system from end to end, and eliminating inefficiencies—whether they’ve existed since installation or crept in over years of operational changes. The reality is that cooling systems often evolve in response to business growth, decline, or shifts in production strategy, but rarely are they redesigned with efficiency in mind.
Take a holistic approach to process cooling, examining the entire system from end to end, and eliminating inefficiencies
Having spent the past 20 years visiting some of the largest manufacturing facilities in the UK, I’ve seen the same fundamental challenges repeat themselves. And one of the biggest threats facing process cooling today isn’t just aging equipment—it’s people.
The Hidden Workforce Crisis in Process Cooling
This isn’t about HR challenges or workforce disputes. The issue is a stark shortage of skilled engineers—specifically, process engineers who understand the design, operation, and intricacies of industrial cooling systems. In almost every facility I visit, there are just one or two individuals who truly understand how the system works. Alarmingly, in nine out of the last ten sites I’ve been to, those key engineers are planning to retire within the next 18 months.
It’s a knowledge gap that is growing wider by the day. Whilst engineering has remained one of the most popular university degree choices in the UK, only 7.1% of engineering students specialise in chemical, process, or energy engineering. Meanwhile, mechanical engineering—more focused on machinery and production—claims a quarter of all engineering graduates. This isn’t just an academic trend; it’s a reflection of an industry-wide mindset that undervalues process cooling.
Only last week, a client described their cooling infrastructure as “an inconvenient necessity” rather than a strategic asset. That perception is a major reason why businesses are willing to invest heavily in cutting-edge production machinery but leave the cooling systems that support them to slowly degrade.
Businesses are willing to invest heavily in cutting-edge production machinery but leave the cooling systems that support them to slowly degrade.
The Real Cost of a Piecemeal Approach
Without knowledgeable process engineers taking ownership of the entire cooling system, manufacturers risk being led by product specialists who only see part of the picture. This isn’t a criticism of suppliers—without innovation from manufacturers, we wouldn’t have the high-efficiency products available today. But the best equipment in the world won’t deliver results if it’s poorly integrated into an outdated system—or worse, unnecessary in the first place.
Consider a recent example. A client was convinced they needed to replace four aging cooling towers, which were well beyond their best-before date. But after a full system analysis, we found that with the cooling capacity they already had on-site, they might only need one far smaller unit—or possibly none at all.
That’s a game-changer. By understanding their system’s actual capacity and requirements, they’re now in a position to make a decision that will significantly cut both capital and operational expenditure. That’s the kind of financial impact that catches the board’s attention.
Are There Hidden Opportunities in Your Cooling System?
If you’re still treating process cooling as an afterthought, you’re missing out on efficiency gains, cost savings, and a more resilient operation. The question is: how much untapped potential is in your system?
A one-day health check could provide the answers. Starting at £2,500, our comprehensive report will identify opportunities for capital and operational savings—before your most experienced engineers take their knowledge with them into retirement.
Book your assessment today.
Richard Crunden
Managing Director
Vistech Cooling Systems Ltd