Overview
We redesigned an existing chiller unit by replacing brittle plastic casings with more durable, impact-resistant materials to meet industrial standards. The electrical control system needed to stay fully functional, as the original casings supported key fixtures and fittings. We upgraded the membrane switches to tamper-proof CE-marked 230V switches and rewired them to work with the existing PCB. The final product used 430-grade stainless steel for durability in corrosive environments and featured an integrated drip tray system. We also included a complete build pack, allowing the client to transition smoothly to full-scale manufacturing.

‍Methodology
Our team started by replacing the chiller’s plastic casings with 430-grade stainless steel to improve durability and resistance to corrosion. We redesigned the electrical control unit to fit all fixtures and fittings inside the new casing. We replaced the old membrane switches with tamper-proof CE-marked 230V switches and rewired them to work with the existing PCB. The final design featured a brushed metal finish and electro-chemical etching for a professional, industrial look, along with a fixed drip tray to ensure reliable functionality and efficient drainage.

‍Results Discussion
The redesign replaced the chiller’s plastic casing with a robust, industrial-grade stainless steel unit, making it capable of withstanding harsh environments. We kept the electrical system fully functional by updating the control unit with CE-marked switches and custom rewiring. Using 430-grade stainless steel provided corrosion resistance and resulted in a brushed finish with clear, etched button labels. The final deliverables included detailed drawings for the electrical system, sheet metal components, and full assembly instructions, giving the client everything needed to move directly into manufacturing.