CHOOSING A CHILLER: 5 FACTORS TO CONSIDER

CHOOSING A CHILLER: 5 FACTORS TO CONSIDER

When it comes to chillers, figuring out where to start is the tricky part. Air-cooled or water-cooled? Used or new? What size do you need? The experts at Cold Shot Chillers cover all of these questions and more in today’s article.       

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What Are Industrial Chillers?

An industrial chiller is a refrigeration system that keeps equipment and materials cool, allowing operations to run smoothly. Air Conditioners dehumidify air while water chiller systems cool down fluids that can be used to condition spaces or cool processes, simply by removing heat. However, these units are not “cooling” or “chilling” anything; they simply remove heat.

Factors to Consider for Your Chiller Choice

There are a few general rules of thumb to keep in mind when selecting a new cooling system. Keep reading to gain a better understanding of the different chiller types available on the market.

1. Size

Size is one of the biggest factors to consider when buying a chiller. Selecting a correctly sized chiller is paramount. A chiller that is too small won’t properly cool your equipment or materials. On the other hand, a chiller that is too large will work just fine, but providing excess capacity will over time fail prematurely due to short cycling. In addition, you’ve spent more money than you needed to. So how do you know what size chiller you need?

Industrial chillers come in a variety of sizes, ranging from ¼ ton to thousands of tons in capacity. We recommend you use a chiller size calculator to determine what size chiller you need for your application. Below are some examples of chiller sizes based on industry standards.

• Medical Chillers – 7 ½ ton and 5-ton chillers; or 12 ½ and 15-ton chillers for cooling multiple medical devices simultaneously
• Welding Chillers – it’s advised to have at least 1-ton of chilling capacity for 100KVA of welder capacity
• Winery Chillers – typically, a 2-ton air cooled chiller is sufficient for most winery applications
• Waterjet Cutting Chillers – common sizes are 2 and 3 ton
• Hydroponic Chillers – sizes generally range from 1.5 to 100 tons
• Flower Chiller – sizes range typically from 2-100 tons

Keep in mind that these sizes are only based on industry standards. Manufacturers like Cold Shot Chillers can design and build custom units of virtually any size. We highly recommend using a chiller sizing tool with exact measurements for the most accurate estimation. You can also reach out to our experienced team for additional help with sizing requirements or general questions.

2. Application

Chillers have various applications for all types of industries. For example, they are used for medical applications such as radiotherapy, PET scans, laboratory operations, and even blood bank refrigeration. In addition, MRI chillers and CT chillers are used frequently in the healthcare sector.

Food processing chillers serve a variety of applications in the food and beverage industry. Depending on your specific setting, you can choose from bakery chillers, winery glycol chillers, brewery glycol chillers, dairy milk chillers, and even commercial yogurt machine chillers.

Metal finishing chillers can be beneficial for paint and powder coating, anodizing, die casting cooling, furnace cooling, quench cooling, and more.

Explosion-proof chillers are commonly used in chemical processing plants, coal plants, oil and gas refineries, and other work environments that interact with flammable gases and vapors.

Cold Shot Chillers offers additional industry-specific chiller types, including laser chillers, plastic processing chillers, government and municipal chillers, welding chillers, and more. 

3. Type

Industrial chillers can be categorized in a few different ways. Let’s take a look at five types of chiller classifications.

• Air Cooled Chillers – Air-cooled systems are generally cheaper than water-cooled chillers. However, they tend to release significant amounts of heat, so these chillers are best-suited for facilities where heat is not an issue.
• Water Cooled Chillers – Water chillers are typically quieter and more efficient than air-cooled chillers. Therefore, they are suitable for commercial-scale and small-scale facilities.
• Portable Chillers – In this case, the term “portable” does not refer to the mobility of the chiller. Instead, it means that a chiller contains all the system’s basic components in a single footprint.
• Stationary Chillers – Chillers that are “stationary” do not include a tank or pump. Instead, they are stand-alone units that must be connected to a reservoir and pump to function.
• Central Chillers – These chillers are used to cool several processes. They can have a portable or stationary configuration, and they can be air-cooled or water-cooled.

4. Pricing

Industrial chillers can range in price anywhere from hundreds to thousands of dollars. As mentioned before, water chillers are typically more expensive than air-cooled chillers. In addition, different chiller manufacturers all design and price their systems uniquely, so make sure to carefully compare prices and weigh your options before making a purchase.

5. Manufacturer

Always familiarize yourself with the manufacturer and their policies ahead of time. Ask the following questions and more before choosing a chiller:

• Do they offer a chiller warranty?
• What’s the turnaround time?
• How are new chillers tested?
• Do they offer chiller accessories and tools?
• How is the chiller prepped for shipment? 
• Has the company been around for a while? The longer a company has been in business chances are good the company is reputable and trustworthy.
• Does the chiller design use any proprietary components? That replacement part might carry a high price tag since these types of parts are generally used to control the chiller. Over time these items become obsolete and no longer supported.
• How easy is it to reach a live person? Can you get technical and commercial issues resolved over the quickly?
• Has the chiller manufacturer built a chiller handling the same type of application or something similar?
• Does the chiller company make it easy to do business with? Can you discuss your application with a knowledgeable technical representative? Can you get a quote issued for your project quickly? Does the submittal information include everything you need about the chiller you are considering?
• Deal directly with the manufacturer to cut out the middleman. This will alleviate any confusion on how your chiller should be configured and possibly save some time and money.

Looking to buy a new or used chiller? Look no further! Cold Shot Chillers is a Houston-based industrial chiller manufacturer with decades of industry experience.

Finding the Right Chiller for Your Company

We hope that you’ve learned some valuable information here that will help you make the best purchase. We’re confident that we can find a solution for you, no matter what you’re looking for!

An industrial water chiller is essential for any facility using large machinery that generates significant heat. These chillers help maintain a low temperature within your facility and cool down internal machine equipment. By understanding how these chillers work, you can make informed decisions about your cooling needs. Let's dive into the details of industrial water chillers.

What is a Chiller?

Chillers are widely used in both commercial and industrial settings. Essentially, a chiller is a refrigeration system designed to cool liquids or mechanical equipment. The primary function of a chiller is to remove unwanted heat while maintaining stable temperature, pressure, and current in the machinery or production process. This is done by circulating a heat-absorbing process through the refrigeration cycle within the chiller.

Contact us to discuss your requirements of Water Cooled Chiller System. Our experienced sales team can help you identify the options that best suit your needs.

Additional reading:
5 Reasons Why Your Business Needs Oxidation Chiller Manufacturer and Supplier？

Industrial chillers are used to control the cooling—either directly or indirectly—of products, mechanisms, and machinery in various industries. Despite the different types of industrial chillers, they all use air or water as a cooling method during the refrigeration cycle.  

For instance, an air-cooled chiller cools the system with fans, while a water-cooled chiller uses circulated water from a cooling tower. These systems can cool water to below ambient temperature or even below freezing. Water chiller capacities are typically measured in cooling tons, KCAL/hr, or BTU/hr. For instance, Creworks' 6-ton water chiller can achieve cooling capacities of up to 61,200 BTUs per hour.

Why Do You Need a Chiller System?

Industrial operations generate heat through friction and high-powered equipment like furnaces or engines, or through temperature-sensitive materials such as plastics. To prolong the lifespan of heavy-duty equipment and speed up production via shorter cycle times, chiller units are installed to circulate cooled liquid through the equipment.

Selecting the right chiller for your application can help you save costs, reduce downtime, and increase production capacity and operational efficiency. The two main types of industrial chillers used today are air-cooled and water-cooled chillers, which we will discuss further.

Types of Industrial Chillers: Air-Cooled vs. Water-Cooled

There are two types of condensers used in chillers: water-cooled and air-cooled. In a refrigerant cycle, the hot refrigerant gas from the compressor needs to be cooled in the condenser. It then enters the expansion valve into the evaporator to generate chilled water and achieve the desired cooling cycle.

Air-Cooled Chillers

Air-cooled chillers have condensers that use ambient air to cool the hot refrigerant gas. These chillers are usually installed in areas with good airflow, as they rely on fans instead of cooling towers to dissipate heat. An air-cooled chiller absorbs heat from processed water and transfers this heat into the air.

Water-Cooled Chillers

Water-cooled chillers have condensers that use water from a cooling tower to cool the refrigerant gas. Once the refrigerant is cooled and released via an expansion valve, it cools the circulating water in the chiller to reach the target temperature. The processed water acts as a medium for heat transfer.

Air or Water Chillers: Which One Suits Your Needs?

Both air-cooled and water-cooled chillers are designed to facilitate the discharge of heat from the production process. They produce the same cooling capacity under the same compressor power. Therefore, your decision should be based on your working environment and the purpose of use.

Creworks, a top manufacturer with over 40 years of experience in the chiller business, is globally recognized in the market.  To learn more about our reliable and customizable chillers for various sectors, explore our Chiller & Cooling Water Series.

How Do Industrial Water Chillers Work?

Nearly every industrial process generates heat. If this unwanted heat accumulates, it can reduce the productivity of your machinery and factory. Excessive heat could even lead to shutdowns or early equipment failure. Incorporating a cooling process into your industrial system design can help avoid these issues.

Components of a Chiller

The essential components of a chiller include a compressor, condenser, expansion valve, and evaporator. These components work together to circulate a refrigerant that removes heat from a process, operation, or space.

Compressor

The compressor is the major component of a refrigeration unit. It circulates the refrigerant (freon gas) and converts it from low-pressure to high-pressure before it travels to the condenser to discharge its heat.

Condenser

The condenser cools the gas by transferring heat from the refrigerant to the outdoor cooling medium (air or water). It also condenses the refrigerant, converting it from a gas to a liquid.

Expansion Valve

The liquid refrigerant passes through the expansion valve before entering the evaporator for heat exchange. The expansion valve lowers the high pressure and temperature of the refrigerant liquid, converting it into a low-pressure, low-temperature wet vapor, which is then sent to the evaporator.

Evaporator

The evaporator is where the actual heat exchange happens. The processed water from the expansion valve enters the evaporator to start the cooling process.

Which Industries Need a Water Chiller?

Water chillers are used in various industries, including:

• Plastic manufacturing and processing
• Metal forming
• Food and beverage processing
• Machinery
• Chemical and pharmaceutical
• Medical (MRI, CT scanner, x-ray, linear accelerator, laboratory)
• Shoe industry
• Laser cutting
• Transportation manufacturing
• Semiconductor
• Composite manufacturing

Things to Consider Before Selecting a Water Chiller System

Using a water chiller in a factory has numerous benefits. However, these benefits can only be realized if you have the right chiller installed. Consider the following questions before purchasing a water chiller system:

• What's the heat load of your intended application?
• What coolant type, target temperature, and flow rate does the chiller system provide?
• In what environment will the water chiller be installed, and what are the site conditions?
• Does this water chiller model meet or exceed the required capacity? (check the chiller performance curves)

Save Time with Creworks' Industrial Commercial Water Chiller

In addition to expert advice, a top-tier manufacturer creates water chiller models that effectively maintain component temperatures during operations, thereby optimizing production efficiency. Here are several advantages of selecting Creworks' 5 ton industrial chiller:

If you are looking for more details, kindly visit Refrigeration Chillers for sale.

• High Cooling Capacity: CREWORKS' CWTH-5 water chiller offers powerful cooling, handling up to BTUs per hour, ensuring effective temperature control for industrial processes.
• Efficient Water Usage: With a spacious 16-gallon (60 L) water tank and a circulation rate of 29 gpm (110 liters per minute), it maximizes cooling efficiency while conserving water.
• User-Friendly Design: Features like an observation window for water level monitoring, corrosion-resistant brass water inlet and outlet ports, and real-time temperature sensors with a digital display ensure easy operation and maintenance.
• Reliable Performance: Equipped with a 7.5 hp compressor using R407C refrigerant, it maintains a stable water-cooling system within 3℃ of a constant temperature, supported by indicator lights and alarms for quick troubleshooting.