Vertical Multi-Zone Temperature Control System for Space-Constrained Roller  

CUSTOMER: CONTITECH, ROLLER HEAD PLANT 2, LOCATED IN KALYANI, INDIA

Customer Challenge 

During the modernization of the Roller Head production line, ContiTech faced a major engineering limitation: there was insufficient floor space for a conventional horizontal Temperature Control Unit.

At the same time, the new TCU had to control 7 independent heating and cooling zones, provide 650 kW cooling capacity and 380 kW heating capacity, operate fully automatically, and comply with Continental’s stringentstandards for electrical design, energy efficiency, maintainability and automation.

The challenge was therefore not only to design a new temperature control system-but to redesign its entire physical architecture to fit within a severely restricted installation footprint while maintaining full accessibility for service. Instead of adapting an existing design, IPECON developed an entirely new vertical (“stacked”) TCU architecture.

Engineering Challenge

The engineering team had to solve several competing requirements simultaneously: 

• minimum installation footprint 

• unrestricted maintenance access 

• modular construction 

• hydraulic performance 

• transportability 

• future serviceability 

Unlike conventional side-by-side layouts, the complete technology had to be arranged over multiple structural levels without compromising hydraulic balance or operator accessibility. This required a completely new mechanical arrangement of:

• central hot-water preparation 

• central cooling module 

• pumping systems 

• electrical cabinet 

• pipe routing 

• service platforms 

• maintenance access zones 

IPECON Solution 

IPECON engineered a multi-level Temperature Control Unit integrating all process modules into one compact vertical platform.

The system combines: 

• centralized hot-water preparation 

• centralized cold-water preparation 

• seven independent mixing circuits 

• four dedicated cooling circuits 

• redundant heat exchangers 

• intelligent Siemens control system 

• fully integrated electrical cabinet 

Despite the compact footprint, every service component—including pumps, valves, filters and sensors—remains individually accessible for inspection and replacement, in accordance with Continental’s maintenance requirements. The TCU was also designed as a pre-assembled modular unit suitable for overseas transport and rapid installation on site.

Technical Highlights 

Vertical engineering concept 

Instead of increasing floor space, IPECON increased engineering density. The complete hydraulic and technological system was distributed vertically, reducing the installation footprint while preserving service accessibility.

Centralized thermal management 

The TCU uses a centralized hot-water preparation circuit together with a centralized cooling circuit supplying multiple independent process zones. 

Redundant critical equipment 

Both heating and cooling circuits include redundant filtration and redundant heat exchangers to maximize production availability. 

Intelligent hydraulic balancing 

Each process zone is independently controlled using proportional mixing valves and variable-speed circulation pumps, ensuring precise temperature control while minimizing energy consumption. The specification also required automatic operation, external shutdown capability and integration with the shopfloor network.

Built for Continental standards 

The system was engineered to satisfy Continental’s demanding standards covering electrical systems, energy efficiency, automation, documentation and maintainability. These standards define requirements for modular electrical design, PLC integration and energy-efficient operation.

Customer Benefits 

• Minimal installation footprint 

• Maximum utilization of available production space 

• Seven independently controlled temperature zones 

• High-capacity centralized heating and cooling 

• Simplified maintenance despite compact design 

• Reduced installation time through modular construction 

• High availability through redundant critical components 

• Ready for future process expansion 

When ContiTech ran out of floor space for a conventional Temperature Control Unit at their Roller Head Plant 2 in Kalyani, India, IPECON went vertical instead. The result: a stacked, multi-zone TCU delivering 650 kW cooling and 380 kW heating across 7 independent zones — in a fraction of the footprint, without sacrificing serviceability.