Lower Carbon, Higher Performance: Transforming Cooling Infrastructure at Rolls-Royce

The Challenge

Rolls-Royce’s shell room is used for painting turbine components, a process that requires temperatures to be maintained below 22°C to ensure product quality and consistency. The existing cooling units had been in operation for approximately 20 years and were reaching the end of their service life.
Operating within a demanding environment containing airborne paint dust, the units had experienced significant wear and required replacement. The challenge was further complicated by the fact that the facility operates 24 hours a day, seven days a week, meaning all works needed to be completed within a live production environment without disrupting manufacturing activities.

Our Approach

Integral Cooling Tech developed a solution that not only replaced the ageing cooling equipment but also improved long-term system performance and maintainability.
A bespoke filtration system was designed and installed beneath the new cooling units. This enhanced filtration arrangement provides greater protection against paint dust contamination while simplifying maintenance activities, helping to extend equipment lifespan and sustain operational efficiency.
Sustainability and future-proofing were key considerations throughout the project. The new systems incorporate highly energy-efficient technology and utilise low Global Warming Potential (GWP) refrigerants, reducing environmental impact while ensuring compliance with evolving industry standards.

The Results

The upgraded cooling solution has delivered immediate operational and environmental benefits:

• Improved temperature stability within the shell room, supporting critical paint processes.
• Approximately 25% greater energy efficiency compared with the previous cooling systems.
• Extended equipment lifespan through enhanced filtration and easier maintenance access.
• Reduced environmental impact through the use of low-GWP refrigerants.
• Zero disruption to production, with no downtime experienced during the paint process throughout the installation programme.

This project demonstrates Integral Cooling Tech’s ability to deliver complex engineering upgrades in critical operational environments. By combining innovative design, sustainability-focused technologies and meticulous project management, Integral Cooling Tech successfully enhanced operational resilience at Rolls-Royce while maintaining uninterrupted production.