Brief
OPTIMISED THERMAL PERFORMANCE
ENGINEERED FOR EXTREMES
A leading global manufacturer of arboriculture machinery approached our engineering team to resolve persistent overheating and fuel inefficiency issues across several of their bestselling wheeled woodchipper models.
These machines, powered by petrol-driven Hyundai Doosan DPF engines, were operating in some of the harshest forestry environments where existing OEM air blast cooling systems consistently underperformed during heavy-duty cycles.
The challenge was clear: to design an intelligent thermal management solution that could withstand extreme environmental conditions, optimise cooling performance, and improve overall machine efficiency - all within the confines of a fixed installation space.
Analysis
Validated Design
& Engineering Support
The client’s brief outlined multiple objectives for the new cooling system:
Optimise thermal management of Engine Jacket Water and Charge Air
Improve fuel efficiency and reduce emissions
Deliver a retrofit solution within a predetermined space envelope
Maintain existing mounting points and fluid ports
Ensure easy access for cleaning, servicing and maintenance
Our engineers conducted an in-depth analysis of the existing thermal system under various real-world operating conditions. Detailed performance data revealed inefficiencies in air flow and heat rejection, particularly under debris-heavy and high-load scenarios typical in forestry work.
Drawing on over 45 years of experience in thermal engineering, the team designed a more efficient air blast, plate and bar combination cooler. Advanced CAD modelling and thermal simulations were used to refine geometry, airflow, and thermal capacity.
Technical data sheets and 3D models were submitted for customer validation before pre-production builds were released for extensive field testing.
Solution
COMPLETE ENGINE
COOLING SYSTEM
The final bespoke cooling pack combined both a radiator, to manage engine jacket water temperature, and a charge air cooler, to reduce exhaust gas temperature prior to turbocharger induction. This high-performance, air-cooled, sandwich-type design was built to excel in extreme duty cycles and debris-heavy conditions.
Key design features included:
Durable, impact-resistant and cleanable surfaces
Chemical-resistant, non-stick coatings for easier maintenance
Easy-access charge-air cooler and sealed surfaces to simplify cleaning
Integrated expansion tank with SAE J164 filler cap and sight glass for improved serviceability
Standardised design adaptable across multiple machine models - varying only the fan and motor assembly
The results were significant:
Enhanced thermal performance under extreme load
Improved fuel efficiency and reduced emissions
Lower maintenance requirements and downtime
Rationalised SKU count and reduced inventory costs for the OEM
From rugged forestry machinery to advanced industrial engines, this project demonstrates how Thermex deliver intelligent, application-specific thermal systems that perform reliably under pressure. Whether off-the-shelf or bespoke, Thermex heat exchangers combine air, oil, and water cooling into fully tested, integrated systems engineered for extreme environments.
Read more about Thermex’s EV & Hybrid Cooling options here.