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Glycol Chillers: The Ultimate FAQ Guide

This guide will help you choose high-quality and reliable glycol chillers.

It will begin by explaining what makes glycol chillers unique, then to applications, benefits, classifications to the working principles, amongst others.

So if you want to be an expert in glycol chillers, read this guide.

What is a Glycol Chiller?

Glycol chillers are special refrigeration systems that use glycol as the main refrigerant for maintaining cool temperatures in different applications.

Glycol chiller

What are the Applications of Glycol Chillers?

You will use the glycol chillers in several industrial applications to cool off different equipment.

It will help in lowering the overall temperatures of different products within a very short period.

Here are some of the applications where glycol chillers come in handy.

· Brewing Industry

You will use the glycol chillers in the brewing industry to cool off different types of equipment.

Apart from that, you will use it to cook different types of liquids such as beverages and alcohol in the breweries.

You can use it in applications such as crash cooling of beer during and after the fermentation process.

What are the Main Parts of the Glycol Chillers?

Glycol chillers are special types of refrigeration systems with special components such as evaporators, condensers, metering devices, and compressors.

Here is a brief description of the main components of the glycol chillers.

· Condensers

You will depend on the glycol chillers to help in the elimination of heat from the glycol refrigerant.

It is available in different sizes and quality specifications depending on your personal or custom requirements.

· Expansion Valve

The expansion valve will come in handy when you will need to increase the volume and reduce the pressure of the refrigerant.

You can choose among the different types of expansion valves including thermal, electronic, pilot operated thermal and fixed orifice expansion valves.

· Water Boxes

You will find the water box in a water-cooled glycol chiller which helps in controlling the flow of water within the chillers.

It will help in the segregation and straight flow of water within the entire glycol chiller system.

· Compressor

You will depend on the compressor to create enough pressure that will move the refrigerant through different points.

Here, you will choose between the four main compressors including scroll, screw, reciprocating, and centrifugal compressors.

· Evaporators

The evaporator will help in the collection of the heat that comes from the system.

It goes ahead and fills up the unwanted heat into the glycol refrigerant to take it to the cooling towers.

· Power Unit

The power unit acts as the main electric power supplier to the glycol chiller systems.

You can control the flow of electric current through the power unit of the glycol chillers.

· Control Panel

You will use the control panel to configure, program, and monitor all the operations of the glycol chillers.

It has quite several specifications that you can rely on to fully control the glycol chillers from remote locations.

How Do the Glycol Chillers Work?

Glycol chillers have refrigeration components and tubings that contain mixtures of glycol and water.

In its cool or chilled state, the glycol water fluid or refrigerant will move from the main storage unit.

Here are the main steps where the glycol-water mixture or fluid will pass through.

· Compressor Unit

It will flow through the compressor unit which will compress the water-glycol fluid and increase the pressure.

It will provide it with the right force that it needs to flow through the entire glycol chiller system.

Depending on the type of compressors, the fluid will develop enough pressure and flow to the next stage.

· Evaporator Unit

Here, the fluid will move to collect the heat that the evaporator collects from the system.

The evaporator uses the help of an ever-flowing fluid such as water which collects the heat from the system application.

As soon as the glycol water fluid mixture reaches the evaporator, it will collect the heat from the flowing water.

After collecting the heat, it will leave the water in a cool state, then allow it to flow back to collect more heat.

The refrigerant will increase in pressure and heat and then change from a liquid state to a gaseous state.

It will then flow straight to the condenser which is the next step in the whole process.

· Condenser Unit

This is the point where the refrigerant will lose the heat that is collected from the evaporator.

The condenser will condense the gaseous fluid by eliminating the heat and reducing the volume.

It will get rid of the heat through the air blowing in the atmosphere of take the heat to the water cooling towers.

This will allow the refrigerant to move slowly from the condenser and to the expansion valve.

· Expansion Valve

Here, the refrigerant will drop the high pressure and then increase the volume of the refrigerant significantly.

This will create enough room for the collection of enough heat from the refrigerant.

It will then allow the refrigerant to flow back to the compressor to start the process all over again.

Which Specifications Do You Consider When Choosing a Glycol Chiller?

When choosing a glycol chiller, there are particular features that you need to pay close attention to.

Here are some of the features that you will pay very close attention to.

· Cooling Capacity of the Glycol Chillers

In this case, you will look at the cooling capacity of the glycol chillers and how fast the chillers work.

Different cooling capacities come with different types of glycol chillers.

· Power Consumption Units

The aim is to reduce the cost of production as much as possible in a bid to maximize profits.

In this case, you should choose a glycol chiller that consumes the least amount of power while delivering efficiently.

· Dimensions of the Glycol Chillers

In this case, you will look at the size of the glycol chillers and how they will assist you in your industrial applications.

You will determine the dimensions by determining the weight, length, width, and height of the glycol chillers.

· Type of Materials

You will also look at the types of materials for making or fabricating the glycol chillers.

The main material for making the glycol chillers is stainless steel which does not corrode easily.

· Proper Control System

You should consider having the latest form of technology when it comes to the control systems on the glycol chillers.

For instance, you should choose a glycol chiller that has a remote control panel to enable remote operations on the chillers.

How do you Maintain Glycol Chillers?

You must maintain your glycol chillers regularly to allow them to work at optimum capacity.

Here are the main factors you need to do to maintain your glycol chillers well.

· Inspect Your Glycol Chillers Regularly

You must maintain regular inspection of the glycol chillers to identify any broken parts or parts that require replacement.

· Keeping Proper Working Records

You must also maintain proper records of how the glycol chillers work daily for proper referencing.

You will be able to compare the records regularly to check if the machine is lacking in some ways.

· Cleaning the Glycol Chillers

It is important to clean the glycol chillers regularly to get rid of debris that might affect the glycol chillers.

· Lubricating the Glycol Chillers

You must also lubricate the moving parts of the glycol chillers to help in reducing the friction that damages the moving parts.

· Replacing the Broken Parts

You should also replace the broken parts on the glycol chillers which you will identify through frequent inspection.

What are the Features of a Glycol Chiller?

Glycol chillers have specific features that help in their proper operations to cool down different systems.

Here are the main features that you have to pay very close attention to.

• Proper temperature control systems with multi-vessel crashing and fermentation temperatures
• Quiet Operations which reduces the amount of noise it produces
• Tidy hose and cable management
• Stainless steel materials with high tensile strength and corrosion resistance.
• Small footprints that vary depending on the type of glycol chillers

How Much Does a Glycol Chiller Cost?

You will spend between 500 and 80,000 US dollars on the purchase of the glycol chillers.

There is a huge price variation between the different types of glycol chillers attributed to:

· Different Sizes of Glycol Chillers

There are different sizes of glycol chillers where the small chillers cost less than the bigger chillers.

· Different Types of Chillers

In this case, you will look at the different types of glycol chillers in terms of the latest technological applications.

Glycol chillers that exhibit the latest forms of technology will often cost more than the others.

· Different Quality Specifications

Here, you will note that high-quality glycol chillers cost a lot more than the low-quality glycol chiller system.

This is because the high-quality glycol chillers use very high-quality materials that will cost more to acquire.

What are the Glycol Chiller System Technical Support Components?

You need to install the glycol chillers alongside the technical support systems for proper chilling services.

Here are the main technical support components that you have in your system must-have.

• Thermal Expansion Valve
• Lock Service Valves
• Refrigeration Solenoid Valve
• Refrigeration Sight Glass
• Refrigeration Filter Dryer
• Liquid Filled Pressure Gauge
• Hi/Low-Pressure Control
• Glycol Pump
• Glycol Bypass valve
• Fan Cycling Valve
• Condenser Fan and Motor
• Condenser Coil
• Compressor
• Compressor Pump Circuit Breakers
• Brazed Plate Heat Exchanger

Which Types of Glycol Can I Use in the Glycol Chillers?

There are two main types of glycol that you can use in the glycol chillers to cool different applications.

Here are the two main types of glycol that you can use.

i. Ethylene Glycol

This is a type of glycol that you can use in industrial applications.

It is often toxic, thus not suitable for use in industrial food applications.

ii. Propylene Glycol

This is a food-grade type of glycol that you can simply use in the cooling of food products.

You can mix it with water to make it more effective in different applications depending on the application requirements.

Which Types of Glycol Piping Do You Use in the Glycol Chillers?

You can use different types of materials to help in the manufacturing of glycol piping systems.

Here are the main materials that you will use in the manufacturing process of glycol chiller pipes.

• Coper Materials
• ABS Plastic Piping
• Pre-Insulated Schedule 80 PVC
• Crosslinked Polyethylene (PEX)
• Nylon Braided Rubber Hose

What are the Factors to Consider When Laying Out, and Designing Your Glycol Chillers?

When designing custom glycol chillers, you should consider the following factors.

Here are the main factors that you need to pay close attention to during the designing process.

· Position of Glycol Chillers

You should position the glycol chillers close to the tanks to reduce restrictions between the tanks and the chillers.

· Do Not Use Excess Pipes or Undersized Pipes

You should avoid using undersized pipes or excess pipes as that might increase glycol flow pressure and compromise cooling jackets.

What are the Benefits of Using the Glycol Chillers?

There are numerous benefits that you can enjoy by using glycol chillers.

Here are some of the advantages of using the glycol chiller.

Glycol chiller system

· High Levels of Durability

You will use the glycol chillers for quite a long period with minimal hitches because of the high durability rates.

It has very strong materials with very high tensile strength and does not corrode easily.

· Antifreeze Properties

Glycol chillers have very high antifreeze properties as glycol does not freeze easily due to low freezing temperatures.

You can, therefore, use the glycol chillers in very cool temperature environments with minimal hitches.

· Easy to Clean and maintain

You will also have an easy time cleaning and maintaining the glycol chillers.

It has very few parts that you can easily remove, clean, and replace immediately.

· Easy to Operate

With modern technological advancements, you can simply operate the glycol chillers.

It gives you the chance to operate the glycol chillers from a remote location.

What are the Disadvantages of Using the Glycol Chillers?

Unfortunately, despite the numerous merits of glycol chillers, there are particular limitations.

Here are the man’s limitations of using the glycol chillers.

· High Cost of Acquisition

You will spend quite a lot of money on purchasing the glycol chillers.

Apart from that, you will spend more on transporting and installing it at the right location.

How Do You Troubleshoot the Glycol Chillers?

It is common to experience setbacks when operating the glycol chillers.

Since it is a big system, you may find it difficult to identify the source of the problems.

In this case, you will troubleshoot the glycol chillers to help in the identification of the problems.

Here are some of the issues that you will identify by troubleshooting the glycol chillers.

· Failure to Power Up

The glycol chillers may fail to power up because of a lack of proper flow of power.

In this case, you may forget to power it up or you may have problems with the power connection units.

You can solve this by switching on the power or replacing the faulty power cables.

· Failure of Fluid (Glycol) to Flow

You might have problems with the proper flow of glycol because of blocked pipes or low levels of glycol.

The glycol may even be contaminated this affecting the proper flow properties of the refrigerant.

You can solve this problem by doing proper maintenance of the entire machine and refilling the refrigerants regularly.

How Can I Increase the Efficiency of the Glycol Chillers?

There are particular secrets that you can use to increase the efficiency of the glycol chillers.

You need to implement such ideas within your glycol chiller applications to have better chilling efficiencies.

Here are some of the factors that you can implement to increase the efficiencies of the glycol chillers.

· Maintain Proper Record Taking

You should take records of the glycol chiller operations daily at a particular point in time.

Having such records in place will help you understand the best operation points of your glycol chiller.

With that information, you will know when the system has a problem and requires proper maintenance.

· Cleaning the Glycol Chillers

You should also have a good cleaning schedule for your glycol chillers which will help with proper fluid flow.

It will help in the elimination of impurities that might block the systems thus causing more problems.

· Disinfecting the Glycol Refrigerants

You should also maintain proper hygiene standards of the glycol refrigerant to eliminate the possibility of contamination.

Contamination might lead to corrosion of the glycol chiller systems or the growth of molds that might block the system.

· Replace the Broken Parts

This involves inspection regularly to identify the problems that might affect the operations of glycol chillers.

You will be able to see parts that are in bad condition for proper replacements when the right time comes.

Is Water the Perfect Alternative to Glycol in the Glycol Chillers?

No. you cannot use water as the perfect alternative in the glycol chillers.

Glycol systems or glycol chillers have special features that work best with glycol or a mixture of both glycol and water.

Apart from that, glycol has particular benefits over water such as:

• Glycol has antifreeze properties which make them better than water in cooler or cold temperatures.
• Glycol also has lubrication properties which help in lubricating the glycol chiller systems
• Glycol has better heat holding capacities in comparison to water and is suitable for long tubing runs.

How Do Glycol Chillers Compare to the Water Chillers?

You can use both water chillers and glycol chillers to maintain cool temperatures in different applications.

Glycol chillers employ the use of glycol as the main refrigerant which helps in the elimination of heat from the system.

Water chillers use water as the main refrigerant which helps in cooling different industrial applications.

Water chiller

Water and glycol have different freezing points which will make one chiller more efficient in cooler applications.

Glycol chillers have a lower freezing point thus making them better than glycol chillers in cooler environments.

In very cold conditions, water chillers are likely to have frozen water, coolants thus making glycol chillers the best option.

On the other hand, water has a better ability to conduct heat, thus more efficient in cooling than glycol chillers.

What is the Difference Between Glycol Chillers and Air Chillers?

Air Chiller

You have the liberty of choosing between the glycol chillers or the air chillers.

Both air chillers and glycol chillers will help in eliminating excess heat from the system applications.

You will note that both glycol and air chillers have similar components including compressors, condensers, evaporators, and expansion valves among others.

You can use glycol refrigerants in air chillers to help in the elimination of excess heat.

On the other hand, you can also have a proper flow of air to help in the glycol chillers cooling systems.

Despite the similarity, you can use water in glycol chillers to cool the system which is impossible for air chillers.

Which Quality Standards Must Glycol Chillers Adhere to?

You must make sure that you get the best quality out of the glycol chillers.

This is possible by looking at the quality certifications of the glycol chillers.

Here are the main quality certifications that your glycol chillers must adhere to.

• DIN Quality Certifications such as DIN EN ISO 9001:2015 and DIN EN ISO 14001:2015
• EG Quality Certifications such as (EG) 303/2008
• CE Labeling Quality Certifications such as EU regulation no. 765/2008
• ELT Quality Certification
• RoHS Quality Certifications such as RoHS 2011/65/EU
• EN Quality Certifications such as EN 12309-2
• JIS Quality Certifications such as JIS B 8622: 2009
• ANSI Quality Certifications such as ANSI/ASHRAE 182 – 2008 and ANSI/AHRI 560
• VDI Quality Certifications such as VDI 4650-2

Which are the Main Important Facts to Look at When Operating a Glycol Chiller?

Glycol chillers are one of the best types of chillers that you can use in cooling different applications.

You must, however, be very careful when operating the glycol chillers to avoid unnecessary accidents.

Here are some of the factors you must take under proper consideration when using glycol chillers.

· Never Use Automotive Grade Anti-freeze

Automotive glycol antifreeze is not proper for industrial glycol chilling applications.

It may lead to numerous inconveniences such as an improper collection of heat from the system.

· Do NOT Mix Glycol Refrigerants

You should maintain one brand of glycol chiller in a particular application.

You should avoid mixing different types of glycols as that might lead to blockage of filters and gelling.

· Choose the Right Type of Glycol

You should understand the main difference between propylene glycol and ethylene glycol.

Ethylene glycol is best for industrial applications while propylene glycol is best for chilling food products.

· Adhere to Local Regulations

You must also have proper knowledge of the regulations for using glycol chiller in your area.

Different regions have different rules that govern the use of glycol chillers which you must pay close attention to.

· Location and Application of Glycol Mixtures

It is also important to know that the location and the application will influence the percentage mixture between glycol and water.

You will have to determine if you will be using the glycol chillers in indoor or outdoor applications.

· Fluid Filtration and Maintenance

It is very important to have proper filtration and maintenance of the glycol fluid to avoid having issues.

This will keep the fluid in perfect condition and will help in maintaining your glycol chillers in great condition.

I hope you got all information you were looking for about glycol chillers.

Still, if you have any questions, feel free to contact TopChiller technicians.

Glycol Chiller-The Ultimate Buying Guide by TopChiller

What is a Glycol Chiller?

Glycol Chiller is a specialized refrigeration system that comprises refrigerant components and a cooling tube that uses the glycol-water mixture as a fluid.

Glycol Chiller is used in popular industries such as food, beverage, brewery, and alcohol industries to cool a variety of liquids, alcohol, beverages, and other drinks.

What is Glycol in a Glycol Chiller?

Glycol is a typically used organic compound being a member of the alcohol family. It is mixed with water and used as a coolant in refrigeration systems.

Glycol is a reliable coolant because of its extraordinary characteristics which include resistance to corrosion in the tubes of the system and anti-freezing properties.

Why Glycol is used in Glycol Chiller?

Glycol is used in Glycol Chiller because of its unusual properties that include:

• Glycol has refrigerant properties that are suitable for use at low temperatures.
• Anti-freezing properties ensure that the coolant stays in a desirable fluid state and does not freeze.
• Glycol being an anti-freezing agent avoids obstruction and blockage in the circulation.
• It increases the efficiency of the refrigerant cycle because of its anti-freezing property even at low temperatures.

What does Glycol do in the Processing System of Glycol Chiller?

Glycol contains unique physical and chemical properties. It plays a vital role in processing systems by adjusting the temperature range of the system.

Glycol has anti-freezing properties and colder temperatures provide temperature flexibility to the tubes and pipes as they pass in the heated and unheated areas.

Non-toxic and non-corrosive, glycol prevents the tubes, screws, pipelines, and coils from corrosion in the processing systems of a Glycol Chiller.

What Types of Glycol can be used in Glycol Chiller?

Glycol being a family member of the alcohol family is used in the Glycol Chiller system but not all types of glycol can be used. Only two types of Glycol can be used which are:

• Ethylene Glycol
• Propylene Glycol

Both these types of glycol are inhibitors and non-hazardous. Propylene glycol has a high viscosity and higher freezing points that make it more thermally efficient for processing systems.

What is the Working Principle of a Glycol Chiller?

Glycol Chiller works on the principle of circulating glycol and water mixture as a coolant in a closed circuit to decrease the temperature of fluid for

a cooling system.

Glycol is mixed with water in an accurate ratio depending upon the system. This water-glycol mixture passes the heat exchangers and cools the vessel, resulting in lowered temperature.

What are the Basic Features of a Glycol Chiller?

A Glycol Chiller has various features for controlling and monitoring different parameters, such as temperature, pressure, glycol percentage, flow rates, and circulating speed.

• Control Panel

A remote control panel is the best feature that permits the entire system access in an outdoor application, controlling rooms, and monitoring setups.

• Closed Auto-Fill Tank

A closed auto-fill tank refers to a pressurized auto-fill tank that aids in maintaining the fluid level and allows pressure systems to reach the tank after one circulation.

• Glycol Auto-Fill Kit

It is a unique feature of a Glycol Chiller that maintains glycol levels in closed circulation systems. This kit also measures the level of circulating glycol in a system.

What are the Major Components of a Glycol Chiller?

A Glycol Chiller comprises a compressor, evaporator, condenser, and a metering device along with other additional components that include:

• Glycol Storage Tank

The glycol storage tank is used to store glycol after the completion of a circulating cycle. It is made up of stainless steel, fiberglass, or polythene.

• Electrical Control Panel

An electrical control panel is a major part of almost every chilling system. An electrical control panel controls the parameters of Glycol Chiller and is installed next to the control panel.

• Glycol Circulation Pump

A glycol circulation pump is designed to circulate glycol at a low-temperature range. The circulation pump circulates glycol from the storage tank to the evaporator and back to the tank.

What are the Types of Glycol Chiller?

There are two basic types of Glycol Chiller that include:

• Packaged Glycol Chiller

Packaged Glycol Chiller has a capacity of 40-60 tons in the systems. Energy-saving compressors and condenser fans are installed to enhance the

the efficiency of the system.

• Portable Glycol Chiller

Portable Glycol Chiller is a smaller unit that is mounted on a caster and provides efficiency. It works in cooling a single machine or process of a manufacturing unit and food industries.

What is the Function of Using Glycol in the Glycol Chiller?

Glycol contains corrosive inhibitors that aid to prolong the life of components of the Glycol Chiller. Its major function is to maintain a cooling system at a slightly lower temperature.

Glycol accommodates the narrow temperature ranges to maximize the system efficiency. The anti-freezing properties enhance the performance and provide reliability.

What are the Advantages of Using Glycol in Glycol Chiller?

A Glycol Chiller provides several advantages over other cooling systems that use ice and water to cool the industrial processes, machinery components, and fluids.

Following are some advantages:

• Glycol has anti-freezing properties that are a game-changer between an ordinary chiller and Glycol Chiller.
• It prevents corrosion among the pipelines and tubes because of its anti-freezing property.
• Anti-freezing properties of glycol enhance system efficiency and performance
• Accommodates narrow temperature ranges.
• To provide constant cooling temperature which protects the machinery from damage because of temperature fluctuations.

Does Glycol Help to Prevent Corrosion in Glycol Chiller System?

Yes, glycol plays a vital role in preventing corrosion in the pipelines and other components of a Glycol Chiller by maintaining the pH level. Glycol has inhibitors that avoid the chances of corrosion.

Additional inhibitors, pH buffers, and biocides in glycol also prevent the growth of bacteria and fungus in the condenser coils. It also extends the life span of Glycol Chiller system components.

What are the Applications of Glycol Chiller?

A Glycol Chiller is a specific type of chilling system that is used in brewing, alcohol, and food industries for various purposes and its major applications include:

• Used to lower down the temperature of a process during production.
• Glycol Chiller is used in fermentation processes in brewing production units.
• Used in industries to cool a variety of liquids such as beverages and alcohol.
• It is used to cool a process, fluid, environment, and mechanical equipment during industrial operation.

What are the Test Parameters of a Glycol Chiller?

It is necessary to test a Glycol Chiller for its performance and efficiency to check if it requires any repair or needs extra troubleshooting to enhance its working capacity. The test parameters include:

• Dosing

This is the most important parameter to take into consideration. The glycol dosage is checked in the equipment to ensure the levels before starting a major process in the unit.

• Leak Testing

Leak testing is also very important to ensure that the circuit is hermetically locked and there are no chances of leakage and wastage of the cooling fluid during circulation and storage.

• Water Treatment

Glycol Chiller water should be checked. It is another important test parameter to test the quality of water that is used in the Glycol Chiller as low-quality water can be the source of corrosion.

What is the Role of Glycol Chiller in Food Industries?

A Glycol Chiller is used in various industries including food industries. It serves as a low-temperature storage application for food products. Some other roles include:

• Prevent spoilage of products.
• Provide consistent temperature.
• Improves food quality by providing consistent low temperatures.
• Inhibits bacterial and fungal growth Increase the shelf life of food products.

What is the Processing of Glycol Chiller?

The basic principle of processing is the same as other air and water-cooled chiller systems. The only difference is that in Glycol Chiller recirculation and processing, fluid is glycol in place of water.

Glycol Chiller starts its processing by the circulation of coolant in the tubing system containing a water-glycol mixture.

Heat exchangers are attached to inlets and outlets. The chilled fluid is pumped into the heat exchanger where heat is absorbed from the process or whatever is attached to the system.

The coolant absorbs heat from the process and transfers it to the Glycol Chiller. Warm fluid is returned to the refrigerant storage tanks and reused in circulation and the same process is repeated in cycles.

What Kinds of Pipelines are used in Glycol Chiller?

Different types of pipelines are used in Glycol Chiller depending upon the capacity and requirements. These pipelines vary depending upon the material and composition such as:

• Copper

Copper pipe is considered a splendid choice for glycol piping, as it is a rigid pipe that provides trouble-free service with no fear of leakage. Copper pipes are expensive as compared to other types.

• Schedule 80 PVC

Schedule 80 PVC is an economical choice of glycol piping that performs well in breweries. 80 PVC are up-high rigid pipes that work great when installed properly.

• ABS Plastic Pipe

ABS are pre-insulated pipes that are expensive but perform great when specifically installed in chilling systems for chilling operations especially in brewing industries.

What is the Role of Condenser in a Glycol Chiller?

A condenser is a major component of the chilling system. Glycol Chiller also uses a condenser to reject heat from the product being cooled by the refrigeration cycles in a cooling system.

The condenser uses ambient air or water to absorb heat from the refrigerant and cool it to convert it into a high-pressure liquid that enters the metering device for further processing.

What is the Role of Compressor in a Glycol Chiller?

A compressor is used in Glycol Chiller to pump out the evaporated refrigerant and compress low pressure and temperature liquid into high temperature and pressure gas.

There are various types of compressors in the Glycol Chiller that includes a screw-type compressor which is highly energy-efficient, soundproof, and has more life span.

What is the Temperature Range in a Glycol Chiller?

Temperature changes at different percentages of glycol. It depends upon the percentage of the glycol used. Glycol has refrigerant properties that are suited for use in chilling systems.

Temperature ranges of a Glycol Chiller are:

• 26°F for 100% glycol
• 18°F for 20% glycol
• 8°F for 30% glycol
• -7°F for 40% glycol
• -29°F for 50% glycol

How can you Determine Glycol Solution Percentage in a Glycol Chiller?

It is very easy and convenient to determine the glycol solution percentage in a Glycol Chiller. A device named a refractometer provides a fast, accurate, and accessible solution for this purpose.

A refractometer measures direct readings of freeze point, concentration, and solution percentage of ethylene or propylene glycol in the Glycol Chiller with the help of a scale.

What are the Considerations in Designing the Layout of a Glycol Chiller?

You should consider several factors in designing and laying out a glycol chilling system:

• Check the position of the Glycol Chiller. Always position the system close to the tanks.
• Always use wide pipelines for continuous flow. Narrow or undersized piping causes

increased pressure of circulating glycol that can damage the fittings.

• Install pressure and temperature gauges in the supply header and place them in a highly visible location.
• Consider adding a bypass valve in the piping system. Set the appropriate pressure of the glycol-water mixed fluid to barely flow through the lines.

In What Ratio Water is Mixed with Glycol in a Glycol Chiller?

Calculating the exact water and glycol ratio is very important for a Glycol Chiller. It depends on the temperature. A higher percentage of glycol boosts the mixture’s anti-freezing properties.

Normally, the ratio of glycol and water mixed fluid is 60/40. Less glycol in the system can cause it to freeze up and potentially bust the pipes and rupture tubes and evaporators.

An accurate ratio of glycol and water is very beneficial in providing instant cooling. In the rapid cooling process, the fluid gets cooled at a very low temperature without freezing the coolant.

How can you Change the Ratio of Mixture in Glycol Chiller?

Normally, glycol and water are mixed at a certain ratio of 60/40. The ratio of glycol and water can be changed on-site in a Glycol Chiller by adjusting according to the requirements.

Once a ratio is disturbed, it can be changed by adding more water to the blend. Calculate the right percentage before adding more water.

Note that water should be filtered, distilled, and treated water so that after mixing it does not change the pH of circulating fluid.

Air pockets are also removed to avoid system frothing in Glycol Chiller.

How can you Select the Best Glycol Chiller for your Industry?

Check your budget and requirements while selecting your Glycol Chiller. Also, consider the following major points:

• A well-sized cooling system enhances the production speed, improves accuracy, and protects the damage. Keep the size in mind while selecting your Glycol Chiller.
• Check the cooling capacity, pressure, and temperature of flow rate.
• Consider the glycol tank capacity so that a fixer will be available in case of temperature spikes up.

How can you Maintain Glycol Level in Glycol Chiller?

Checking glycol levels in a Glycol Chiller is an important part of the maintenance checklist. Glycol level can get disturbed due to fluctuation in temperature or due to any leakage.

Check the pipes if there is any leakage or not. Then perform fluid analysis by using a fluid analysis kit. With the manufacturer’s guideline fluid analysis comes with a sample bottle and a protocol.

You can send your sample to the manufacturer and get results via email. Take steps to maintain and control the glycol level. It is also important to note the concentration of glycol.

A freeze point chart can be used to get an estimate of the concentration of glycol at different temperatures. If the concentration is low or high, use a glycol concentration calculator to fix it.

How much does a Glycol Chiller Cost?

A Glycol Chiller can be made customized depending upon your budget, requirements of the processes, and capacity of the chilling system. Cost varies on the addition of more tanks.

Normally, an average Glycol Chiller with good efficiency and size ranges from $2000 to $3000, which performs well for industrial operations and provides services for 15 years.

How can you Maintain your Glycol Chiller?

A Glycol Chiller can give extra years of service if it is maintained well. Conducting regular maintenance sessions is very important to increase the service of your chilling system.

The maintenance includes the following major elements:

• Glycol Bath Temperature

Keep an eye on the glycol bath temperature after every two weeks. Check it according to

the manufacturer’s guidelines and if it is under range. In case of any fluctuation, look for a suitable solution to keep it in range.

• Glycol Mixture

It is very important to maintain the level and percentage of glycol mixture. Check the level, condition, and freezing point of the glycol-water mixture fluid after every six months.

• Glycol Bath

Check the lid on the glycol bath to prevent the dilution of the glycol-water mixture by water

vapors.

Which Industries Use Glycol Chiller?

Several industries use Glycol Chiller for various purposes such as cooling the process fluid, providing a cooling effect to the environment, and cooling the machinery equipment.

Food industries use it for chilling the food products and maintaining a low temperature to avoid food spoilage such as cheese, butter, yogurt, ice cream, and other dairy products.

Brewing industries use Glycol Chiller for providing consistent temperatures at a low range in alcohol production. Fermentation processes also require low temperatures for alcohol yield.

Another important use of this chilling system is in beverage industries that use refrigeration systems to cool the processing fluids, drinks, and other beverages in the manufacturing units.

Which Type of Glycol is Best to Use in a Glycol Chiller?

Two types of glycol are used in a Glycol Chiller that includes ethylene glycol and propylene glycol. Both these kinds have the following properties:

• Inhabitant
• Non-corrosive
• Non-hazardous
• Anti-freezing

Propylene glycol is less toxic and contains anti-freezing properties is considered best to use. Propylene-based glycols are inhibited and non-hazardous and include food-grade ingredients.

How can you Test Glycol in your Glycol Chiller?

It is very important to keep testing glycol in a Glycol Chiller to maintain its level, percentage, and freezing point. The recommended tool for this purpose is a refractometer that can test glycol efficiently.

A refractometer checks the refractive index of glycol that measures the angle at which light passes through the circulating material by a few drops of the sample.

A prism is used to determine the refractive index of glycol at a specific angle and the screen displays the readings that also represent its anti-freezing point.

What are the Adjustments of Glycol with Environment in a Glycol Chiller?

Note that environment is a critical condition to consider while choosing a correct Glycol Chiller. If you place the system outdoor, more glycol is required as the low temperature can result in freezing the glycol.

On the other hand, if the Glycol Chiller is installed indoors, chances of freezing become zero as it does not require much glycol. Maintain the exact percentage of glycol at different temperatures.

Low and high temperatures require different concentrations of glycol. Glycol concentration calculator can be used to determine the exact concentration whether the Glycol Chiller is placed indoor or outdoor.

What Safety Devices are used in a Glycol Chiller?

It includes a freeze alarm, temperature alarm, and high head pressure alarm.

• High Head Pressure Alarm 

A high head pressure alarm activates when load peaks the normal values and ambient temperature is very high because of some unknown reasons. The alarm shows a sign with a light.

• Thermostat

A thermostat is a temperature control that acts as a safety device in a Glycol Chiller. Check the set point of the thermostat. The thermostat shuts down in case a set point is raised in the chilling system.

• Freeze Alarm

It is a major safety device that warns about extreme conditions during which the Glycol Chiller system encounters a freeze alarm. Compressor or evaporator failure can cause the freeze alarm to trip.

What are the Causes of Freeze Alarm in your Glycol Chiller?

There are several causes of freeze alarm in your Glycol Chiller. Restrictions cause freeze alarms and create issues resulting in freeze alarms.

Some of the causes are given as follows:

• Glycol Pump

If the glycol pump trips due to overload or any other reason, it becomes difficult to turn on the pump. Shut down the electric supply to avoid a freeze alarm.

• Flow Restriction

A flow restriction is another major reason to cause freeze alarm. It can be due to a closed valve or the pump failing due to an overload of fermenters. Check these minor restrictions to avoid freeze alarm.

• Pump Rotation

Another major cause of freeze alarm is lack of flow due to pump rotation restriction.

The reduced flow reduces the temperatures of the evaporator often leading to freezing up.

• Glycol Solution

Check the glycol percentage, level, volume, and concentration of glycol in a Glycol Chiller. To avoid a freeze alarm, make sure all the pumps are turned on.

What are the Considerations Before Setting your Glycol Chiller?

There are a few considerations that should be kept in mind before setting your Glycol Chiller.

Check for the location and environmental space available. Other major considerations include:

• Space and Location

Check the space and location of Glycol Chiller.

Choose an area that can easily adjust more storage tanks for glycerol. The environment must be ventilated and airy to adjust the Glycol Chiller pipelines and tanks.

• Glycol Concentration

It is important to note the glycol concentration using a refractometer before setting a Glycol Chiller. Monitored concentration can protect the system components from critical damage.

• Control Panel

Check the control panels if they are operative enough to display flow rates, levels, and concentration.

It is very important to check that the control panel is working efficiently in a chilling system.

What are the Safety Instructions for your Glycol Chiller?

Here are some major safety instructions including:

• Turn off the Glycol Chiller completely before cleaning it.
• Do not store explosive substances such as aerosol cans near a Glycol Chiller.
• Replace the damaged cord or plug as soon as possible to avoid any short-circuiting.
• Always use food-grade propylene glycol in the Glycol Chiller. Check the manufacturer’s specifications for proper guidance.
• Avoid moving and handling the Glycol Chiller and its components that can cause damage or leakage.
• Use no additional mechanical devices to boost the refrigeration cycle other than the manufacturer’s recommendations.