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Carclo, a global leader in precision manufacturing, is renowned for its high-quality diagnostic and medical devices, as well as advanced technology components. Their dedication to innovation and quality has earned them a trusted reputation across sectors where reliability is critical. As part of their drive for continuous improvement, Carclo sought to enhance operational efficiency by reducing injection moulding cycle times—without compromising their exacting standards.
Injection moulding plays a central role in Carclo’s operations, and even marginal gains in efficiency can translate into substantial improvements in output and profitability. To help achieve this, Carclo partnered with Summit Process Cooling, a company with over 30 years’ experience in delivering tailored water-cooling systems across a range of industries.
Summit recommended trialling Frigel Microgel units—compact, high-performance temperature control systems specifically designed to optimise plastics manufacturing. These systems offer precise temperature regulation, promising better process stability and reduced cycle times. Although initially met with some scepticism from Carclo’s Manufacturing Director, Andy Fay, a trial of the technology went ahead in late 2024.
“As part of our continuous improvement programme, we worked with Summit to review cooling for our mould tools,” explained Andy. “They recommended Microgel units positioned lineside for each tool. A single unit, model RSM80/9, was provided for trial. Stuart from Summit gave excellent support and training, and the result was a 10% cycle time reduction—greatly improving throughput.”
The trial tested both single and dual-zone Microgel units, yielding better-than-expected results. A reduction of 0.6 seconds per cycle brought the moulding process down to under 9 seconds, significantly enhancing output.
Buoyed by this success, Carclo expanded the initiative. “We went on to purchase two dual chiller units, which could serve two machines independently,” said Andy. “These RSD80/12 models offered flexible control, and again with Summit’s support, installation was seamless. We recorded an average cycle time reduction of 9% across four lines. Based on these figures, we expect a return on investment within 12 months.”
The productivity gains were immediate—so much so that Carclo found it challenging to maintain pace with the supply of packaging materials for the finished products. These efficiency improvements have helped increase profitability and reinforced Carclo’s ability to meet rising demand.
The project also highlighted the value of expert technical support. Andy praised Stuart Nesbitt of Summit Process Cooling for his role in ensuring the project’s success. “I can only commend his installation work and excellent phone support, particularly when we hit a snag during a tool change. His expertise helped us resolve it quickly and get the most out of the equipment.”
This successful collaboration between Carclo and Summit illustrates how advanced cooling systems like the Frigel Microgel range can deliver real-world benefits—from cycle time reductions to improved process stability. The transformation reflects Carclo’s unwavering commitment to innovation and efficiency in precision manufacturing.
Summit Process Cooling’s bespoke approach and focus on customer success were key to the project’s achievements. By thoroughly understanding Carclo’s needs and offering a tailored solution, they strengthened the relationship and delivered measurable results.
With Frigel Microgel systems now fully integrated into their operations, Carclo is well-positioned to continue leading in the precision manufacturing sector. Their partnership with Summit provides a strong foundation for future advancements, ensuring they maintain their reputation for quality, performance and forward-thinking solutions.
For more information on Carclo Boosts Productivity with Summit Process Cooling and Frigel Microgel Systems talk to Summit Process Cooling