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Industrial Air Chillers: The Ultimate FAQ Guide

Before you import industrial air chillers from China, read this guide.

It has all information that will help you get energy-saving and efficient industrial chillers.

Keep reading to learn more.

What is an Industrial Air Chiller?

Industrial air chillers are devices that you will use to eliminate heat from industrial applications using air.

In other words, the device will absorb heat from the process water and eliminate it into the surrounding air.

Industrial air chiller

What are the Benefits of the Industrial Air Chillers?

You will maintain the temperatures of your equipment using the air chillers thus keeping them safe and durable.

In addition to that, you will experience a cool working environment among other benefits including:

· Tight Control of Temperature

Your industrial air chillers will provide tight control of temperature with cost-effective solutions through variable frequency drives.

Apart from that, it incorporates recirculation tanks that maintain high levels of temperature control.

· Scalable Cooling Process

It can support over 1000 equipment at the same time thus giving you the perfect opportunity to expand.

No matter your starting point, you can use industrial air chillers that you can expand as your industrial applications grow.

· Continuous Operations

It also comes complete with a couple of redundancy options that help in keeping your facilities cool throughout.

This will allow you to proceed with the production process entirely with very minimal interruptions.

· High Durability Levels

Industrial air chillers are highly durable machines that will serve you for a very long time.

It comes complete with very high-quality materials that do not corrode easily and have high tensile strength.

Are there Limitations to using Industrial Air Chillers?

Unfortunately, industrial air chillers also have particular limitations that should never discourage you.

Here are some of the limitations of using industrial air chillers.

· High Cost of Acquisition

You will spend quite a lot of money on the purchase of industrial air chillers.

The price may even go higher in cases where you will need custom-made industrial air chillers.

· Complicated Installation Process

Apart from the high cost of purchasing the machine, you will also go through a rigorous process of installing the machine.

You will need the assistance of experts who usually come at a price thus increasing the installation cost.

·  High Noise Levels

Industrial air chillers might irritate you with the high noise that it produces in comparison to industrial water chillers.

You can rest easy knowing that modern industrial chiller’s technological advancements are working to sort this out.

What are the Components of the Industrial Air Chillers?

Industrial air chillers work best with the collaboration of all the components within the machine.

Here are the main components that work simultaneously to increase the efficiency of industrial air chillers.

· Refrigerant

The refrigerant is a fluid that is responsible for carrying or eliminating the heat from the process water.

It flows through all the major industrial air chiller components changing its form as it assists in eliminating excess heat.

· Compressors

You will depend on the compressor to compress the refrigerant to increase the pressure and speed of low.

It will also increase the volume of the refrigerant in readiness for picking up the heat within the evaporator.

· Evaporator

This is the part of the industrial air chiller where the refrigerant collects the heat from the process water.

It has numerous tubes with running water that carry the heat from the industrial process applications.

· Condenser

After collecting the heat, the refrigerant will change in state to a gaseous state and flow straight to the condenser.

The condenser is the part of the industrial air chillers where the air flows and carries away the excess heat from the refrigerant.

It will then condense the refrigerant and change its state from a gas into a liquid flowing at low pressure.

· Expansion Valve

At the expansion valve, the liquid refrigerant will undergo another process of compression that will expand it as it flows.

It will increase in volume in readiness for picking more heat as it flows back into the compressor.

The expansion valve will also control the amount of refrigerant that it allows to flow straight to the compressor.

· Control Panel

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

It has an HMI user interface and a touch screen that you will use to program the operations of the machine.

You can also depend on the control panel to work well even with controls from a safe and remote distance.

Industrial air chiller semi-hermetic screw compressor

How Does an Industrial Air Chiller Work?

Well, the industrial air chillers have one of the simplest working principles that you will ever come across.

It employs the principle of expansion, evaporation, and condensation to eliminate excess heat from different industrial applications.

First, the refrigerant will flow into the compressor which will compress it to increase volume and speed.

In its liquid state, the refrigerant will move at high velocity straight to the evaporator.

While at the evaporator, it will collect the heat from the water running through the system.

As the water runs through the system it picks the heat that the industrial applications emit thus cooling them out.

The water collects the heat which will increase its temperatures considerably as it flows to the evaporation chamber.

While at the evaporation chamber, the refrigerant will pick the heat and cool the water.

In the process, the refrigerant heats up and changes its form from liquid to gas flowing at high pressure.

After that, it will flow straight to the condenser which will eliminate the heat from the evaporator.

Since it is an industrial air chiller, the main cooling agent is air which takes away the heat from the refrigerant.

It cools down the refrigerant thus changing its state from gas to liquid at very low pressure.

It will flow to the expansion valve while the air blows off the heat thus leaving it very cool.

The expansion valve will expand the liquid refrigerant and push it back to the compressor as the process continues.

Which is the Best Location for an Industrial Air Chiller?

Well, industrial air chillers are best for outdoor locations where they can have access to excess flow of air.

You will, therefore, find a spot outside your industry where you will install industrial air chillers.

In addition to that, you can have a mechanical room with plenty of ventilation for proper air access or flow.

This will enable the industrial air chillers to have access to the air that it needs to cool down their equipment.

It will also have proper housing that will protect it from damage from other weather elements.

Outdoor installed Industrial air chiller

How Do You Increase the Efficiency of an Industrial Air Chiller?

You should strive to get the best out of your industrial air chillers by increasing their working efficiency.

Increasing the working efficiency of the industrial air chillers means enabling them to work at optimum capacity.

Here are some of the factors to consider when optimizing the operations of industrial air chillers.

Maintain a Proper Work Report

You should take records of how the industrial air chillers work regularly for proper record tracking.

With these records, you will be able to monitor the operations of the machine and know when anything is a miss.

Proper Maintenance Schedule

You should have a proper maintenance schedule that you have to follow to the letter.

It should guide on the period when you will have to clean every part of the industrial air chillers.

Do Routine Inspection

You must also conduct routine inspections of the industrial air chiller parts to confirm their working conditions.

With this, you will have the opportunity to identify parts that are not working properly and replace them.

Lubricate the Machine

You must also provide proper lubrication of the moving parts on the machine to reduce friction.

Treat the Process Water

You need to treat the process of water regularly to eliminate contamination.

Apart from that, you will be able to reduce the chances of product corrosion with contaminated water.

Maintain Proper Fluid Levels

You should also ensure that the fluids such as water, refrigerants, and lubricants are at the right levels.

Apart from that, you must ensure that they are of good quality and replace them in case the quality deteriorates.

What is the Difference Between Industrial Air Chillers and Industrial Water Chillers?

The main difference that you should note is the chilling agent between the two types of chillers.

Industrial air chillers use air as the main chilling agent while industrial water chillers depend on water as a chilling agent.

Apart from that, you will house the industrial water chillers in a mechanical room and the industrial air chillers outside.

In addition to that. Industrial air chillers produce more noise than industrial water chillers.

Despite the above differences, industrial air chillers and industrial water chillers have more or less similar working principles.

The components on the industrial air chillers and industrial water chillers also have more or less similar characteristics.

Industrial water chiller

How Do You Troubleshoot an Industrial Air Chiller?

There are particular situations where air chillers might encounter problems during the operation process.

In such a case, you will troubleshoot the machine to help in identifying the faults on the machine.

Here are some of the problems that you might encounter through proper troubleshooting techniques.

· Failure of Industrial Air Chillers to Power Up

There are situations when your industrial air chillers may fail to power up due to improper connections.

You can sort this out by checking the entire power line and switching it on to solve the problem entirely.

· Insufficient Flow of Fluids

You may also experience a situation where the fluid does not flow well due to different reasons such as:

i. Process Restrictions

ii. Pump Failure

iii. Blocked Fluid Filters

iv. Small Process Piping

You should get a technician who will tell you the exact problem with the system and sort it out faster.

· Insufficient or No Cooling

Your machine might not be producing the right cooling temperatures because of the following reasons.

i. Fluctuating or improper line voltage

ii. Iced Up Evaporators

iii. Leaks of the Refrigerants

iv. Clogged air condensers and filters

You can sort this out by checking the entire system in the presence of an expert technician.

He will be able to sort out the issues and help in the restoration of normal working conditions.

Proper maintenance of the machine will also help in avoiding such problems.

Apart from that, performing routine inspections of the machines will also help in identifying the problems early.

How do you Maintain Industrial Air Chiller?

Maintaining your industrial air chiller is the only sure way of perfect working conditions and durability.

Implying that you must maintain your industrial air chiller regularly to increase efficiency and durability.

Here are the major maintenance features that you need to conduct on your industrial air chiller.

• Cleaning all the parts of the industrial air chillers to limit the chances of blocking or corroding the system.
• Treating the process fluids regularly to avoid any chances of contamination within the system.
• Replacing the broken parts of the industrial water chillers in time before it causes further damage.
• Lubricating the moving parts on the machine to eliminate the dangers of damage from friction.
• Maintaining proper levels of the process fluids such as water, refrigerant, and lubricating oil.

You should also ensure that you have a proper maintenance schedule that you follow strictly.

Apart from that, doing routine inspections of the entire system will help in identifying faults for replacement purposes.

Finally, you can install software that will inform you of pending maintenance or even abrupt maintenance requirements.

Industrial air chiller maintenance

Do You Supply Portable Industrial Air Chillers?

We do supply portable air chillers according to your specifications.

All you have to do is specify the type of portable chillers that you want.

We ensure that the industrial air chillers are light in weight, easy to package and move from place to place.

Portable industrial air chiller

What are Stationary Industrial Air Chillers?

Stationary industrial air chillers are devices that you will use to cool different industrial applications using air.

Just from the name, you will note that the machine is stationary and is not easy to move from one place to another.

Usually, it is bigger and heavier thus limiting the chances of moving it from one place to another.

In addition to that, you might have to install it on-site with the help of the manufacturer.

How Much Do Industrial Air Chillers Cost?

The cost of industrial air chillers usually varies depending on the chilling capacity of the industrial air chillers.

Apart from that, the industrial air chillers also vary in cost due to the different types of industrial chillers in the market.

You will pay between 10,000 to 90,000 US dollars for the industrial air chillers.

What are the Main Applications of the Industrial Air Chillers?

You will use the industrial air chillers in quite a several industrial applications.

Here are some of the industrial applications where you will use industrial air chillers.

• Plastics Industry such as injection molding
• Food and Beverage Industry
• Pharmaceutical and Chemicals Industry
• Commercial Printing Industry
• Transportation Manufacturing Industry
• Metal Finishing Industry
• Composite Manufacturing Industry
• Laser Cutting Industry
• Machine Tooling and Die-Cutting Industry
• Semi-Conductors Industry

How Do Scroll Industrial Air Chillers Compare to Screw Industrial Air Chillers?

Industrial scroll chiller depends on different sets of interlocking scrolls which pressurize the refrigerants.

You will use them well for smaller and single equipment cooling needs making them perfect for sporadic applications.

On the other hand, screw industrial chillers depend on the force and leverage of the screws to compress refrigerants.

You can use them for both light as well as heavy-duty applications with power ranging between 38 – 214 HP.

Industrial air cooled screw chiller

What are Semi-hermetic Industrial Air Chillers?

These are industrial air chillers that you will use in very large industrial applications.

It is available in different compressor horsepower ranging from 25 – 100 and more.

You can customize it with numerous options such as:

• Air – or -Water Cooled Industrial Air Chillers
• Varying Compressor Powers ranging from 25 to 100 HP.
• Large industrial refrigeration and cooling needs

Do You Supply Remote Condenser Systems in Industrial Air Chillers?

We also supply remote condenser systems that give you the chance to separate compressors and condensers.

It is the best option that you can use in corrosive environments as well as places with poor heat and air ventilation.

How Many Customization Options of Industrial Air Chillers Do You Have?

The best thing about industrial air chillers is the freedom and capacity of customization.

Implying that you can easily customize your industrial chillers according to your specifications.

Here are the main customization options that you should look at.

Full or Partial Redundancy

You can have peace of mind that your processes and equipment are safe from heat destruction in the presence of industrial air chillers.

In that case, the main customization options that you should look at include:

i. Full capacity redundancy

ii. Full electrical isolation

iii. Dual or multi-circuit units

iv. Auto-changeover redundant pumps

Heat Exchanger and Tank

You must also have a good look at the heat exchangers and tanks with several options such as:

i. Remote or Onboard Pump and Tank Packages

ii. Fluid Level Sight Glasses

iii. Low-Level Tank Indicators and Alarm Systems

iv. Variable Frequency Drives for different Pumps

v. Custom Fittings for Tanks

Controls

Here, you can include different features such as smart technologies and custom control options.

Some of the custom control options that you can choose from include:

i. Custom Programs for Different Application Controls

ii. Micro-Controller Standards for remote login access and tighter process controls

iii.  Central Controls for Numerous Units

iv. Remote and On-board Touchscreen Options

v. Text and Email Alert Systems (In case of an emergency)

What Should you Consider when Buying Industrial Air Chillers?

Well, just like any other substance, you must have a proper plan on the specifications you want on the products.

In the case of purchasing industrial air chillers, you need to look at the following specification.

1) Energy Efficiency

In the current world, the aim is to reduce the cost of production through any means possible and that includes saving energy costs.

It is the reason why you should consider purchasing industrial air chillers that consume very little energy.

2) Cooling Capacity

In this case, you will look at how much equipment the industrial air chillers can cool off and at what particular period.

The good news is, you can increase the cooling capacity to accommodate the expansion of your industrial applications.

3) Controls

It is also important to ensure that you have the latest form of control systems with HMI and touch screen.

Apart from that, your industrial air chillers must also have controls that allow you to operate the machine remotely.

4) Cost or Budget

You should also have a proper budget where you will plan on how much money you will spend on purchasing the chillers.

You should remember that the higher the cost of the machine, the more efficient and technologically advanced it is.

Which Quality Standards Should Industrial Air Chiller conform to?

One of the most significant factors that you must consider is the quality of the industrial air chillers.

You must make sure that your industrial air chillers conform to the international standards of quality.

Implying that it is safe for you.

Besides, it has high quality and durable materials for construction.

Here are the main quality standards that your industrial air chillers must adhere to.

• CE Quality Standards
• Current Good Manufacturing Practices (cGMP) Quality Standards
• EN Quality Standards such as EN 12309 – 2
• DIN Quality Standards such as DIN 33830-4
• JIS Quality Standards such as JIS B 8622: 2009
• ANSI Quality Standards such as ANSI/AHRI 560 or ANSI/ASHRAE 182 – 2008
• VDI Quality Standards such as VDI 4650 – 2

In short, your industrial chiller system must conform to these quality standards.

This is what differentiates TopChiller from other companies in the industry.

Our industrial chillers are designed and manufactured to conform to the highest quality standards.

Contact us today for all your affordable and efficient industrial chillers.

100% quality tested industrial air chiller