Integrated Cooling Systems

1. Addressing the critical challenge of integrated cooling

For the industry leader and operations manager, managing a modern production plant requires a constant balance between reducing operating cost, optimizing plant efficiency, and simplifying management. Energy and raw material rates have become substantial: for this reason, the efficient handling of water cooling also becomes a fundamental strategic lever.

Often, those who manage heat dissipation in industrial processes are not just looking for a cooling tower, but need a complete solution for efficient and automated management, with some critical issues to govern.

• High or volatile operating cost. The increase in energy prices and the need for prudent water management require uncompromised efficiency. MITA integrated systems are designed to significantly reduce the use of electricity and water and the cost of industrial fluid treatment, optimizing operation and avoiding waste throughout the day and year.

• Maximum reliability and operational continuity. Overheating or uncontrolled temperature fluctuation can lead to costly operational downtime and material waste. Our integrated solution provides temperature stability through a thermal flywheel effect and offers significant autonomy in case of a temporary water supply interruption. It also reduces the wear and tear of the electromechanical part, lowering maintenance costs.

• Need for a single point of contact. Upgrading or installing a cooling system can involve coordinating with multiple suppliers, with a considerable expenditure of time and resources. MITA’s integrated system is a pre-assembled and plug-and-play solution that integrates every key component, from water treatment to the pumping group and control panel, ensuring a single trusted partner for the entire plant. This also reduces installation and testing costs.

• Automation and circularity. In addition to cost savings, this system facilitates integration with company management systems, allowing for remote monitoring, big data collection, and predictive maintenance, contributing to a more sustainable operation. Automated treatment also helps maintain proper water quality, reducing discharge and associated costs.

MITA Cooling Technologies understands that this challenge requires a comprehensive solution. Our integrated system is designed to solve the critical challenges of your production process, ensuring energy efficiency, operational stability, and environmental responsibility.

2. Complete guide to advanced systems for cooling towers: what they are and when they are needed

An integrated cooling system from MITA is a complete solution, specifically designed for the efficient and automated management of the evaporative cooling tower. It consists of a structure, typically a monolithic reinforced concrete basin, which serves a dual function: containing the industrial water and acting as a support surface or base for the evaporative tower. This structure also incorporates a technical room that houses all the necessary equipment for water management and system control.

This system is designed to integrate every key component of a cooling plant into a quickly assemblable unit, ready for immediate connection to the customer’s hydraulic and electrical system (a “plug and play” solution). The solution is also verified and tested by MITA before shipment, simulating its operation.

You need a MITA integrated cooling system in these scenarios.

• When looking for an “all-in-one” cooling solution: if you need a consolidated system that combines the function of water collection, treatment, pumping, and control, as well as providing a solid base for your cooling tower, an integrated unit is ideal.

• For greater efficiency and automation: this system is specifically designed for more efficient and automatic management of the evaporative tower, reducing manual intervention and optimizing performance.

• To simplify the project phase: the integrated system significantly reduces the complexity of design, assembly, and commissioning, as it is pre-engineered and ready for quick connection.

• When water quality and consumption are a critical aspect: the system includes a complete water treatment functionality (dosing, salinity control, softening) to prevent scaling and corrosion, reduce water usage, and lower treatment costs.

• For better temperature stability and operational autonomy: the large water storage basin provides a thermal flywheel effect, ensuring a stable temperature and offering a buffer in case of a temporary water supply interruption.

• When looking for a single point of contact: MITA Cooling Technologies offers a complete and tested solution with a guaranteed result, allowing you to rely on a single supplier for the entire plant.

3. Types of MITA integrated systems and cooling stations

MITA Cooling Technologies offers two main types of integrated cooling systems: MITA System A and MITA System B. Both solutions are designed for the efficient and automatic management of evaporative towers and coolers, significantly reducing the design and assembly phases for the customer. They provide a single point of contact for the entire plant.

• MITA System A is made with a single rectangular monolithic reinforced concrete basin, complete with an internal dividing wall to separate hot and cold water. It is coupled with a technical room with a mixed steel/aluminum structure and closure in 25mm sandwich panels for insulation. This solution is ideal for small and medium-sized evaporative cooling towers and installations with contained power requirements, offering a small footprint. It offers a thermal power from 151 kW to 1,279 kW, with a water flow rate from 13 m³/h to 110 m³/h and a storage volume between 5 m³ and 8.5 m³. Each basin is equipped with a manhole for inspection and cleaning.

• MITA System B, on the other hand, consists of a monolithic reinforced concrete structure that integrates two external basins, with an interposed technical room for housing the equipment. The two basins guarantee greater water storage, allowing the management of higher-capacity plants, and permit the positioning of dual-cell evaporative towers above the unit. The models of MITA System B offer a thermal power from 163 kW to 2,907 kW, with water flow rates from 100 m³/h to 250 m³/h and storage volumes between 10 m³ and 20 m³. They also include a manhole for inspection and cleaning.

Both systems are “plug and play” solutions, pre-tested and ready for connection. The main advantages: high efficiency, temperature stability, simplicity of management, cost reduction, and Industry 4.0 compatibility.

4. State-of-the-Art Components in MITA's Advanced Integrated Cooling Systems

Reliability, operational continuity, resource optimization: these are the advantages that MITA Cooling Technologies wants to offer its customers through integrated systems for cooling water management.

Each unit consists of a complete water treatment system, a pumping group with a hydraulic connection, an electrical command and control panel, a containment box (technical room), and a monolithic reinforced concrete water collection basin. It also includes essential electrical services such as automatic lighting, a service power outlet, and antifreeze protection via an electric heater.

Below are the systems that make up MITA System A and MITA System B.

• Pumping. The system is equipped with a separate dual hydraulic circuit – a tower circuit and a user circuit – each managed by a dedicated pumping group for greater flexibility. Both circuits are managed by inverters, ensuring adaptability to the thermal load, significant energy savings, safe operation, and a reduced noise level. The pump is a standardized, monobloc centrifugal pump with direct motor-pump coupling, compliant with the EN 733 standard for reliability and interchangeability. It is equipped with an anti-vibration joint, a butterfly valve, and a check valve.

• Intelligent control panel. The system management is entrusted to a sophisticated electrical command and power panel, designed for the automatic operation of the cooling circuit with an evaporative tower. A touch-screen PLC ensures maximum control security, a programmable function, and clear alarm signaling with a historical data log. Remote control functionality is also available via a start/stop command and a general alarm contact. The panel has IP54 protection.

• Precision sensors. The unit is equipped with high-precision 4-20 mA sensors for temperature control and pressure control (316 stainless steel sensor for inverter regulation). The water level is monitored by a 4-20 mA sensor paired with a capacitive safety sensor to protect the pump from low water levels, with transparent piping for visual inspection.

• Automated water treatment system. Fundamental for efficiency, water quality is managed by equipment designed to prevent scaling, corrosion, and organic contamination.

  • The DOSC (dosing and salinity control) provides proportional dosing of an anti-scaling, anti-corrosive, and biocide product based on actual water usage, with salinity controlled by automatic timed blowdown.

  • The SAL CONTROL offers precise salinity management via timed blowdown or an inductive/resistive conductivity meter.

  • The electronic water softener (CAB and VD), including the dual-column volumetric regeneration system, ensures a continuous supply of softened water by removing calcium and magnesium salts, reducing scaling and improving operational savings.
    Water Treatment for Integrated Cooling Systems

• Robust assembly and connectivity: all internal equipment is pre-connected hydraulically and electrically within the central unit. The piping uses black steel with submerged arc welding and a self-centering joint, or a galvanized threaded connection for smaller diameters, reinforced with an anti-vibration joint and secured to the structure. The electrical connection uses a double-insulated multi-polar cable with IP55 protection, compliant with the CEI-UNI standard.

Different systems, a single goal: to manage cooling water efficiently, safely, and automatically.

Cooling Tower Water Treatment: what to know

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5. Application and Case Study of MITA Integrated Cooling Systems

MITA integrated systems are designed to provide robust and efficient water management and a base for cooling towers in various industrial sectors. While they are broadly applicable to any industrial activity requiring precise cooling and efficient water management, their main strength lies where the efficient and automated management of an evaporative tower and its hydraulic circuit is crucial for optimal performance and resource utilization.

Here are some notable examples demonstrating its effectiveness in demanding environments.

• Foundry and Metals Industry: Fonderia Casati. This historic company from Varese, Italy, successfully integrated the MITA cooling system to automate its industrial processes and maintain European competitiveness, leveraging the solution’s Industry 4.0 capabilities. In 2019, MITA supplied Fonderia Casati with a PMS-type evaporative cooling tower and an integrated cooling station (EasyBox – MITA System A) for water management and remote monitoring, supporting a new induction furnace that required about 400 kW of cooling power. This integrated unit includes a monolithic reinforced concrete basin with a dividing partition to separate hot and cold water and a technical room with a touch-screen PLC for automatic control of pumps, fan group, water pressure and salinity, level, and chemical dosing. The system is Industry 4.0 compatible, allowing data exchange with the company’s management system via Modbus TCP protocol over Ethernet, leading to optimized water and energy use. This also helped reduce installation and maintenance costs thanks to the pre-assembled components.

• Plastics and Rubber: Iltar-Italbox Spa. For their new production plant in Hungary in 2023, Iltar-Italbox required a high-performance, low-noise cooling system to support expanded polypropylene molding lines, which involved a thermal jump of over 40°C and a thermal power of 2,125 kW. MITA provided a PME 2854 E 2V SILENT open-circuit cooling tower, the MITA Control System (MCS) with inverter control for energy and water savings, and an integrated cooling station MITA System B/X. This integrated unit features a monolithic reinforced concrete basin for water containment and a technical room for chemical dosing, salinity control, and centralized parameter management. The solution ensured the desired performance, low noise, and allowed for remote control of the tower’s operations from the group’s Italian headquarters.

• Food Industry: Vinegar Factory (Reggio Emilia). In 2023, a historic balsamic vinegar producer in the province of Reggio Emilia, Italy, needed to optimize the cooling of its fermenters, requiring a water flow rate of 190 m³/h and outlet temperatures below the wet-bulb temperature even in hot summers, integrating with existing MITA towers. MITA supplied a PME 5704 E Silent cooling tower, an Easyblock 200 – MITA System B integrated cooling station, and a Frigofluid (part of MITA Group) RWE 450/4ax-ST HT air-cooled chiller. This combination ensures precise temperature control for the fermenters even during summer peaks, improved operational efficiency, allowed for optimal system integration, and reduced noise emissions. The Easyblock 200 station facilitates the optimization of the user circuit and the tower’s water management. The success was also due to the synergy between the systems of MITA Cooling Technologies and Frigofluid.

7. The MITA Advantage: Beyond being a supplier of an integrated cooling system

Choosing MITA means collaborating with a company that offers a comprehensive approach to industrial cooling.

We are not a simple manufacturer of an integrated cooling unit, we are your cooling and refrigeration consultant, dedicated to optimizing your resource and your productivity. We have always based our commitment on some key points.

• Consultative approach: we delve into your process, your challenge, and your specific goal, providing a tailor-made solution rather than just a piece of equipment.

• Advanced selection software: our expertise is backed by advanced software for performance analysis and energy optimization, ensuring the selection of the best cooler for your project.

• Focus on Total Cost of Ownership (TCO): we help you minimize electricity and water use, reduce maintenance cost due to lower electromechanical wear and tear, and prevent downtime, thus significantly lowering the overall operational expenditure.

• Energy optimization specialist: our system incorporates functionality such as the MITA Control System (MCS) with inverter and Industry 4.0 compatibility for remote monitoring, allowing for dynamic adaptation to the thermal load, ensuring maximum efficiency, and reducing noise.

• Complete support: from initial consultation and plant assessment to custom design, hydraulic and electrical connection, and after-sales service that includes an inspection, remote management, and a spare part, we provide end-to-end support.

• Italian engineering: our solution represents Made in Italy technology, available throughout the European market, reflecting a high standard of quality and reliability.

Cooling Advisors

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8. Let's talk about your need for an integrated cooling system

Ready to optimize your industrial cooling and water management process? The MITA Cooling Technologies team is at your disposal to:

• discuss your specific application and cooling challenge,

• provide a technical evaluation and suggest the most suitable integrated unit,

• offer a competitive quote,

• explain how our detailed selection process ensures maximum energy efficiency and the optimal solution for your needs.

Take the next step towards reliable, efficient, and sustainable industrial cooling with the MITA integrated system.

Do you need info?

Contact our Italian and European Sales Partners.