H. EssersCold Tank Revival: Innovative PCB Upgrades for Extended Service Life

Long story short

H.Essers, a leading European logistics provider specializing in transport and supply chain solutions, faced a critical challenge: an obsolete PCB essential for powering their cooling liquid bulk containers was failing and no longer available. They needed a reliable, long-term solution that seamlessly integrated with their existing system. CTRL Engineering stepped in to reverse-engineer and enhance the design, delivering a custom relay board that not only replicated but improved the original functionality. The result? A future-proof solution ensuring uninterrupted operations, increased reliability, and long-term efficiency.

“In this project, we didn’t just replace the PCB board—we turned a risk into an opportunity by redesigning it for greater durability and future-proofing H.Essers’ operations.” 💡🔧🚀”
Thomas Joris – Development Engineer at CTRL engineering

The Challenge: A Mission-Critical Component No Longer Available

H.Essers’ cooling liquid bulk containers play a vital role in their logistics operations, ensuring temperature-sensitive goods are transported under optimal conditions. The original PCB controlling these containers was responsible for executing commands, regulating power distribution, and managing high-voltage switching between 380V and 460V. Over time, the component had become prone to failure, causing disruptions and increasing maintenance costs. The situation worsened when the PCB was discontinued, leaving H.Essers with no direct replacement and a growing risk to their operational efficiency.

Replacing the PCB with an off-the-shelf alternative was not an option. The system required a seamless integration with existing control logic while addressing the weaknesses of the outdated design. A tailor-made solution was essential—one that would not only restore functionality but also enhance the overall reliability and durability of the cooling tank operations. H.Essers needed a partner who could analyze the original design, identify failure points, and engineer a next-generation replacement built for long-term performance.

CTRL Engineering’s Recipe for Success

CTRL Engineering started by conducting a thorough analysis of the existing system and operational requirements. Understanding the specific challenges—such as managing high inrush currents and ensuring precise power control—was crucial in designing a reliable replacement. We identified key weaknesses in the outdated PCB and re-engineered the design to improve durability, efficiency, and long-term stability.

The new relay board was developed using high-quality components capable of withstanding harsh environmental conditions. Our engineers optimized the circuit layout to ensure seamless communication with the existing control logic while enhancing performance under heavy electrical loads. Each design decision was made with longevity in mind, eliminating the failure points of the obsolete PCB and ensuring reliable operation for years to come.

A prototype was built and subjected to rigorous real-world testing. This phase was critical in validating the board’s ability to handle demanding voltages and high inrush currents without failure. The testing process allowed for fine-tuning and adjustments to guarantee optimal performance before full-scale deployment.

Once the prototype was approved, we proceeded with manufacturing and integrating the new relay board into H.Essers’ cooling container systems. Installation was executed smoothly, ensuring minimal disruption to ongoing operations. Post-installation, we provided ongoing support, closely monitoring performance and addressing any potential concerns to guarantee long-term reliability.

The Outcome: A Reliable, Future-Proof Solution

What began as a pressing operational risk for H.Essers became an opportunity to enhance their systems. By replacing their obsolete PCB with a custom-engineered relay board, CTRL Engineering not only restored system functionality but also delivered a superior solution with improved reliability, efficiency, and durability. The enhanced design ensures that H.Essers’ cooling tanks operate seamlessly, reducing maintenance efforts and mitigating the risk of future disruptions.

Why it matters to you?

H.Essers’ challenge highlights a common issue in industrial automation: component obsolescence can disrupt operations and increase costs. Businesses need more than a quick fix—they require a long-term solution that enhances performance and minimizes risks. CTRL Engineering specializes in designing and integrating custom solutions that extend the lifespan of critical systems, reduce downtime, and improve efficiency.

Whether you need a replacement, retrofit, or a brand-new solution, our expertise ensures seamless integration, improved performance, and long-term reliability.