Fletcher Insulation

Located in Dandenong South, Victoria, Fletcher Insulation is one of Australia’s leading manufacturers of insulation products, supplying residential, commercial and industrial projects across the country.

To support the ongoing operation of this critical manufacturing facility, Premiair was engaged to deliver an urgent cooling solution that restored system capacity, reduced operational risk and maintained business continuity while a long-term plant replacement strategy was implemented.

Fletcher Insulation’s chilled water plant consisted of two chillers, with one unit having reached the end of its operational life and no longer functioning. This left the facility relying entirely on a single remaining chiller, creating a critical lack of redundancy.

During routine servicing and fault investigation, Premiair identified that the remaining operational chiller had suffered a heat exchanger failure. Replacement of the heat exchanger was required; however, the lead time for the replacement component was approximately 20 weeks.

With no viable short-term repair option available and the facility requiring uninterrupted operation, an alternative solution was needed to restore cooling capacity and minimise operational risk.

Premiair proposed the replacement of the non-operational end-of-life chiller with a new Mitsubishi Electric chiller, providing an immediate solution to restore chilled water capacity to the site.

The new chiller was supplied, installed, commissioned, and integrated into the existing chilled water system, allowing the facility to continue operating while the replacement heat exchanger for the second chiller was sourced.

Once the heat exchanger became available, Premiair returned to site and completed the repair of the second chiller, restoring the plant to full operational capacity with complete redundancy.