Discover how Prijai engineered and produced a unique coil solution designed for high heat loads, precise specifications, and repeatable production in collaboration with a top data center cooling OEM.
The Challenge: Cooling That Can’t Afford to Stop
Rack densities continue to rise as AI and high-performance computing workloads increase, and a modern data center operates around the clock. The cooling system must continuously remove the additional heat produced by more computation in the same footprint.
The coil is at the heart of that system. The coil determines how well heat is transferred from air or fluid to the cooling loop, regardless of whether it is located in a distant condenser, thermal wall unit, rear door heat exchanger, or CRAH unit.
A leading data-centre cooling OEM approached Prijai with a requirement for a coil that had to meet three demands at once:
Thermal: reject high heat loads reliably under continuous duty
Dimensional: fit tightly defined equipment envelopes and airflow paths
Production: be manufactured repeatably, at scale, with consistent quality
A coil that performs well in a lab but can’t be built consistently is a risk for the OEM. The project needed engineering and manufacturing to be solved together.
Step 1: Understanding the Requirement
Every Prijai engagement starts with the application, not the catalogue. The team worked with the OEM to understand:
Thermal load and target performance
System configuration and cooling architecture
Airflow requirements and allowable pressure drop
Space constraints and mounting details
Operating conditions and the working fluid
Expected production volumes
This follows the process Prijai uses across its data-centre work: the customer shares requirements, Prijai engineers the right solution, and the product is built, tested and delivered.
Step 2: Engineering the Coil Around the System
In high-density cooling, small design choices add up. Prijai’s engineers tuned the coil’s key parameters to the OEM’s equipment rather than adapting a standard product:
Coil dimensions and face area, matched to the unit’s envelope
Fin and tube configuration, balanced between heat transfer and airside pressure drop
Circuiting, set for the fluid flow and thermal duty
Materials, selected for performance, durability and the operating environment
Thermal capacity, sized to the target heat load with the OEM’s operating margins in mind
Prijai has built 500+ heat exchanger configurations over more than three decades, so the team could draw on a deep library of designs and decide which approach suited this application.
Step 3: Manufacturing for Precision and Repeatability
Prijai manufactures across a network of five operational plants, with two more underway, in Maharashtra. The facilities cover roughly 17,000 sq. m. and are built for Fin & Tube Heat Exchangers, OEM assemblies and copper system tubing.
For this project, manufacturing was planned alongside the design:
Controlled processes for tube expansion, brazing and assembly, so every coil meets the same specification
Dimensional discipline, so each coil fits the OEM’s unit without rework on their line
Quality checks at defined stages, with performance and integrity testing before dispatch
Capacity planning to support the OEM’s ramp-up from first units to volume
With annual capacity above 200,000 units and experience delivering 100+ customised OEM products, Prijai’s setup is built to take a validated design into stable production.
Step 4: Testing, Quality and Delivery
Reliability is a requirement in critical cooling. Before leaving the facility, every coil underwent performance and quality inspections, and Prijai’s quality procedures ensure uniform thermal behavior throughout batches.
The strategy also included delivery. Serving clients in more than 12 nations in North America, Europe, the Middle East, and Australia, Prijai oversees the entire process from manufacturing to logistics to maintain OEM production deadlines.
The Outcome
The OEM received a coil solution that was:
Engineered for the application: thermally matched to a high-density cooling system
Dimensionally accurate: designed to fit the unit
Repeatable at scale: consistent from one batch to the next
Supported end to end: one partner from design through delivery
Key Takeaways for Data-Centre Cooling OEMs
Engineer and manufacture together. Designs that account for production realities reach volume faster and with fewer surprises.
Customisation matters in high-density environments. Dimensions, circuiting and materials should follow your system, not the other way round.
Consistency is a performance feature. Coils that perform identically from the first unit to the ten-thousandth keep your own product reliable.
Choose a partner who scales with you. Capacity, quality systems and multi-plant manufacturing give you room to grow.
Partner with Prijai
Since 1983, Prijai has been providing thermal solutions, ranging from CRAH units and rear door heat exchangers to remote condensers and thermal wall units. We would like to speak with you if you are creating a data-center cooling system and require a coil partner capable of engineering, manufacturing, and delivery.