Thermocycle Chiller Decommissioning & Removal for Cummins Inc

Project Overview

We carried out the decommissioning and removal of a Thermocycle chiller at Cummins Inc.’s facility on Yarm Road, Darlington. The project required a fully managed approach, including system isolation, refrigerant recovery, and unit preparation for safe lifting and transport. All works were completed in full compliance with current environmental and safety regulations, with removal undertaken by Ian Thompson Recycling Ltd.

The Challenge

Decommissioning industrial HVAC equipment of this scale requires careful coordination, technical expertise, and strict adherence to regulatory standards. The project involved safely recovering refrigerants in line with F-Gas requirements, managing compressor oil and associated waste responsibly, and coordinating lifting operations within a live industrial environment. Ensuring safe access for crane operations while minimising disruption to site activities was a key consideration throughout.

Our Approach

We delivered a complete, turnkey solution, managing all aspects of the decommissioning process. The system was safely isolated, and all refrigerants were fully recovered and contained in accordance with F-Gas regulations. Compressor oil was then drained, handled, and prepared for compliant disposal using approved environmental procedures. Working in close collaboration with the client, all necessary mechanical disconnections were completed, including the safe isolation of electrical supplies and the draining and disconnection of associated pipework. This ensured the chiller was left in a stable and secure condition, ready for removal.

The unit was then prepared for lifting, with all necessary measures in place to support safe crane operations. Once lifted, the chiller was loaded onto an HGV for transport and removed from the site efficiently, with recycling managed through our trusted partner Ian Thompson.

Health, Safety & Compliance

Safety and compliance were central to the successful delivery of this project. All activities were carried out in accordance with UK health and safety legislation, supported by detailed Risk Assessments and Method Statements. Particular care was taken to ensure the safe handling and disposal of refrigerants and oils, with clear coordination between all parties to manage site access, isolation procedures, and lifting operations.

The Outcome

The project was completed on schedule and without incident, with all works delivered in full compliance with environmental and F-Gas regulations. Disruption to site operations was kept to a minimum, and the chiller was safely removed and prepared for recycling in line with industry best practice.

What This Means for Our Clients

This project demonstrates our ability to deliver efficient, compliant, and fully managed decommissioning solutions for industrial HVAC systems. From refrigerant recovery through to plant removal and recycling, we provide a seamless end-to-end service that ensures safety, compliance, and minimal operational disruption.

Need Support with Chiller Decommissioning?

We can provide expert support for commercial chiller removal, refrigerant recovery, and industrial plant decommissioning. Get in touch with our team to discuss your requirements and find out how we can support your next project.