Industrial Ice Storage and Direct Cooling: The Future of Sustainable Process Cooling
Industrial ice storage systems combined with direct cooling represent one of the most advanced solutions for energy-efficient industrial process cooling. These systems store thermal energy as ice during off-peak periods and release it when cooling demand peaks – enabling load shifting, cost savings, and CO₂ reduction.
HTT AG’s sustainable cooling technology is engineered for reliability, flexibility, and long-term efficiency in energy-intensive industries.
Understanding the Principle of Industrial Ice Storage
An industrial ice storage system utilizes water as a natural and safe energy storage medium. During periods of low electricity tariffs, chillers or heat pumps produce cooling capacity that freezes water into ice. This stored energy is later released during production hours to supply chilled process water.
The result:
- Decoupled electricity consumption and cooling demand
- Reduced peak load on chillers
- Increased operational efficiency and energy savings
Modern control systems continuously optimize charging and discharging cycles, aligning them with energy tariffs, renewable generation, and production schedules.
How the Combination Works: Direct Cooling Meets Thermal Energy Storage
When direct cooling using ice water chillers is combined with thermal ice storage, industries gain the best of both worlds – instant cooling performance and strategic energy flexibility.
- Direct Cooling: Provides immediate process cooling via ice water or refrigerant loops.
- Ice Storage: Builds up cooling capacity at night or during renewable energy peaks.
This hybrid configuration minimizes system losses and adapts dynamically to variable production demands – a decisive advantage for process water cooling, industrial refrigeration, and sustainable plant operation.
Advantages of Combining Ice Storage and Direct Cooling
- Energy and Cost Efficiency: Shifts consumption to low-tariff hours and reduces chiller runtime.
- Process Stability: Delivers consistent cooling output even during peak loads.
- Grid Relief and CO₂ Reduction: Enables smart load management and renewable integration.
- System Flexibility: Supports modular expansion and integration into intelligent energy management systems.
- Funding Opportunities: Eligible for government incentives promoting energy-efficient cooling systems.
Interested in reducing your facility’s energy costs? Contact HTT AG to discuss your customized industrial ice storage solution.
Industrial Applications
Industrial ice water systems are widely implemented in sectors requiring stable and high cooling capacities, including:
- Food and beverage processing
- Chemical and pharmaceutical production
- Plastics manufacturing
- Data centers and large HVAC systems
- Energy-intensive industrial facilities
These sustainable cooling systems help industries meet decarbonization goals while ensuring operational reliability and cost-effectiveness.
Sustainability and Energy Efficiency in Practice
By converting off-peak electrical energy into stored cooling capacity, ice storage systems avoid peak load spikes and contribute to grid stability.
When combined with photovoltaic or wind energy systems, these technologies enable CO₂-reduced industrial cooling that integrates seamlessly into energy storage and management platforms.
Over time, operational cost reductions and subsidy programs make these systems a profitable and sustainable investment.
Technical Overview: Industrial Ice Storage and Direct Cooling
| Parameter | Description |
| Cooling medium | Water / Ice |
| Construction types | Falling Film, Pillow Plate |
| Typical storage capacity | 200 kWh – several MWh |
| Cooling generation | Chiller or heat pump |
| Operation mode | Charging off-peak, discharging at demand peak |
| Application areas | Process cooling, industrial HVAC, food industry |
| Core advantages | Energy savings, grid stability, CO₂ reduction |
Take the Next Step Toward Sustainable Cooling
With more than 50 years of experience, HTT AG delivers custom-engineered ice storage and direct cooling systems for industrial process optimization.
Our pillow plate heat exchangers and energy storage technologies help companies achieve maximum efficiency and long-term sustainability.
Let’s discuss your project. Contact HTT AG or request a project consultation today.
Frequently asked questions: Industrial Ice Storage and Direct Cooling
A thermal energy storage system that produces and stores ice during off-peak hours to supply cooling energy during peak periods – reducing energy costs and peak loads.
By shifting energy use to off-peak times and lowering chiller load, ice storage significantly enhances overall system efficiency and CO₂ reduction.
Industries with continuous or high cooling demand – such as food & beverage, chemical, pharma, plastics, and data centers –benefit most from this sustainable cooling technology.
- Internal melting (high density, slow discharge)
- External melting (fast discharge, lower density)
- Combined systems (balanced performance)
Direct cooling uses chilled water directly in the process, while indirect systems transfer cold via heat exchangers. Direct cooling provides faster response and lower losses.
Yes – ice storage and renewables form an ideal match, converting surplus green power into stored cooling capacity for later use.
We have always assimilated engineering science and thermodynamics optimally in the various manufacturing processes.
Thermodynamicists,mechanical engineers and welding engineers define the dimensioning, design and construction of customised heat exchanger panels and systems in materials ranging from mild and austenitic steels through to titanium, and ensure successful distribution of their work worldwide.
In doing so they fall back on production engineering expertise and calculations developed in the course of the past hundred years that are still being continuously optimised in an ongoing process.
In the perception of our customers, the Buco product stands for:
Technical and process-oriented consulting
Thermodynamic efficiency
Quality and longevity
