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Industrial Water Chillers: The Ultimate FAQ Guide

I know you’re looking for an energy-efficient and reliable industrial water chiller.

That’s why this guide will answer all questions you have been asking about these industrial chillers.

Whether you want to learn about the working principle, maintenance, improving efficiency, and safety features – you will find everything right here.

What are Industrial Water Chillers?

Industrial water chillers are cooling devices that use water among other integral components to cool off industrial applications.

Industrial water chiller

Which Applications Require Industrial Water Chiller?

You can use an industrial water chiller in a wide range of industrial applications.

Here are some of the main industrial applications that use industrial water chillers.

· Metal Forming Industry

You will use the industrial water chillers in the metal forming industry to cool different machines.

The machines you will cool off include resistance welding, welding, rolling mills, presses, machine tools, extruders, profiling, polishing, and plating machinery.

· Chemical and Pharmaceutical Industry

You will also use industrial water chillers in the chemical and pharmaceutical industry.

It will assist in the cooling of laboratory, jacketed vessels, polyurethane foam mixers, natural gas, industrial cleaning, solvents, and paints.

· Food and Drinks Industry

In the food and drinks industry, you will use industrial water chillers to cool different types of machines.

The machines you will cool include breweries, wineries, distilleries, dairy, bottling, bakeries, food storage, carbonation, and confectionery machines.

· Laser Machines

It will come in handy when cooling different laser machines such as CO2 lasers, diode/solid-state lasers, and Nd: Yage lasers.

· Plastic and Rubber Industry

In the plastic and rubber industry, industrial water chillers assist in chilling different machines.

Some of the machines include presses, injection molding, PET, thermoforming, extrusion, and sheet profile, as well as blow molding machines.

Medical Industry

You will also use the industrial water chillers in the medical industry to cool medical machines.

Some of the machines to cool down include MRI. CT scanner, X-Ray, linear accelerator, laboratory, and healthcare equipment.

Industrial water chillers are widely used in the food and drinks industry

How Do You Choose an Industrial Water Chiller?

When choosing an industrial chiller, there are specific factors that you have to pay close attention to.

You need to look at features that will fit well with your application requirements.

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

· Dimensions of the Machine

You will have to look at the size of the industrial water chillers that you will need for your specific applications.

Here, you will choose an industrial water chiller size that will comfortably cool down your devices.

· Cooling Capacity

You must also look at the cooling requirements of your industrial applications in terms of maximum heat temperatures.

You will ensure that the industrial water chiller has the capability of cooling all your machines within a particular time frame.

· Controls

Industrial water chillers have specific control systems that allow you to configure, control, and monitor the operations.

You should consider going for the latest form of technological controls that will allow you remote control as well.

· Energy Efficiency

The most important factor to look at is saving the cost of production by using the most energy-efficient machines.

In that case, you will choose the most energy-efficient type of industrial water chiller to help in the chilling process.

· Cost or Budget

You must also have a particular working budget which will dictate the type of machine you will purchase.

You must work within your budget and get the most efficient types of machines with better technology.

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

Industrial water chillers and industrial air chillers are devices that you will use in cooling different industrial applications.

The main difference between industrial water chillers and industrial air chillers is the cooling agent.

Industrial air chillers use air as the main cooling agent while industrial water chillers use water as the main cooling agent.

Apart from that, the working principles of the industrial air chillers and industrial water chillers also differ considerably.

In many cases, you will place the industrial water chillers in a mechanical room to protect them from external weather effects.

On the other hand, you will place the industrial air chillers outside the building where there is plenty of fresh air supply.

If not, you can place the industrial air chillers in mechanical rooms that have plenty of ventilation.

Industrial air chiller

How Do You Determine the Right Size of an Industrial Water Chiller?

You must select the right type of industrial water chiller that will fit your application requirements.

This is because undersized chillers may not have the capability of cooling your devices well.

On the flip side, oversized chillers may not work at the efficient level required and may waste energy.

In that case, you will have to calculate the right size of the industrial water chillers by using the size calculator.

In the industrial chillers size calculator, you will need to have the following information.

• Gallons of Water Per Minute
• Temperature Differences
• Calculate the BTU per hour
• Calculate the tonnage of cooling required

You must have accurate data for these calculations to avoid under or oversizing the industrial water chillers.

The automatic calculator will give you the right size of industrial water chillers that you need for your applications.

What are the Benefits of Using the Industrial Water Chillers?

Industrial water chillers have numerous benefits that will boost the efficiency of your industrial applications.

Here are some of the benefits you will derive from using industrial water chillers.

· Improved Productivity

You will have reduced downtime and an increase in the productivity of your industrial products.

It will lead to very little wastes and fewer interruptions during the production process of different products.

· Equipment Protection

It will protect the valuable production equipment from the effects of high temperatures or heat conditions.

It will help in protecting your investments from destruction thus increasing the service life of the machines.

· Optimized Operating Limits and Process Controls

You might spend a lot on the purchase of modern and highly sophisticated equipment but you will improve production efficiency.

Apart from that, you will reduce downtime thus improving the economically viable industrial production processes.

· Reduction in Maintenance and Operation Costs

You will also reduce the amount of money you will be spending on maintaining the different types of machines.

This will translate to a reduction in the overall cost of producing different products thus increasing the profits.

· Saves Water

These systems recirculate and reuse water thus reducing wastage of water in the environment.

It will also help in saving the cost of water that you usually pay to the water providers.

· Flexible

The industrial water chillers are flexible and you can customize them to fit your application requirements.

What are the Components of an Industrial Water Chiller?

Industrial water chillers come complete with different components that perform different functions.

Here are the main components that your industrial water chiller must have.

· Compressors

The compressor is responsible for creating a great pressure difference that will push the refrigerant to the condenser.

There are different types of compressors which include centrifugal, screw, reciprocal, and scroll compressors.

· Condensers

The condenser is responsible for the removal of heat that the refrigerant picked from the industrial machines.

In this case, you will use the water-cooled condenser since we are using industrial water chillers.

· Expansion Valve

You will depend on the expansion valve to expand the refrigerant thus increasing the volume and reducing the overall pressure.

This will make the refrigerant better at picking unwanted heat from the evaporator and transporting it to the condenser.

· Evaporator

You will use the evaporator to pick the excess heat from the industrial application machines to the refrigerants.

It has water flowing through the system that collects the heat as the refrigerant takes it away.

· Power Unit

It is responsible for controlling the flow o electric power to the entire industrial water chiller applications.

It has various components that will control the amount, speed, and flow of the electric current through the system.

· Control Panel

This is the unit that has all the possible control mechanisms for configuring, programming, and monitoring the industrial water chillers.

It has technological advancements that will allow you to remotely control all the functions of the industrial water chillers.

Industrial water chiller control system

How Does an Industrial Water Chiller Work?

Well, the whole process begins when you configure the industrial water chiller with specific working specifications.

As soon as the industrial water chiller is on, the process will begin with the flow of water with the evaporator.

The water will flow continuously within the evaporator and collect heat from the heat emitting industrial application.

The temperatures of the water will increase as it collects more heat from the industrial application.

As the hot water flows back to the evaporator, it encounters low pressure and refrigerant.

The refrigerant will collect the heat and flow directly to the condenser while leaving the water cool.

The compressor will compress the refrigerant to increase the pressure and speed of moving the refrigerant.

At a high speed, the refrigerant will flow from the compressor to the condenser.

Here, the condenser will eliminate the heat from the refrigerant thus turning it back into liquid form.

After that, the water chiller will use water to eliminate the heat to the water towers and dispose of the heat.

The liquid refrigerant will then flow to the expansion valve which will increase the volume while reducing the pressure.

Finally, it will flow back to the evaporator where it will begin the whole process once again.

How do you Increase the Efficiency of Industrial Water Chillers?

You can increase the efficiency of the industrial water chillers by improving the maintenance of the machine.

Here are some of the factors you should consider to increase the efficiency of the industrial chillers.

Maintaining Daily Operation Logs

You should have records of your daily operations and how the machine performs within 24 hours of operation.

A comparison of the daily data will help you determine a decrease in performance and hence the time for service.

Keeping the Tubes Clean

You should maintain the cleanliness of the industrial water chiller tubes to improve the heat transfer efficiency.

It will allow the proper flow of refrigerants and water through the tubes thus saving time and increasing efficiency.

Ensuring Leak Free Units

You will also make sure that all the units are leak-free thus ensuring no wastage of resources in the cooling process.

You should conduct quarterly tests on the industrial water chillers to find out if there are leaks on the system.

Sustain Treatment of Water

You will also ensure that you sustain the water treatment program to ensure that the water is always clean and contaminant-free.

Contaminants in the water may cause problems within the system thus reducing the overall efficiency of the whole system.

Analysis of Refrigerants and the Oil

You should also analyze the refrigerants and oil after a particular time frame to check on their quality.

In this case, you will be able to do proper replacements and refills at the right time before refrigerants and oils expire.

Do Industrial Water Chillers have Limitations?

Unfortunately, no matter how efficient the industrial water chillers are, you will have limitations.

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

High Cost of Purchase and Installation

You must prepare yourself adequately with a proper budget to fund the purchase of industrial water chillers.

It is often quite expensive and many people might not afford to purchase and install the industrial water chillers.

Requires Mechanical Room

You must also construct a mechanical room where you will house the industrial water chillers from destructive weather elements.

This will increase the overall cost of purchase and installation of the industrial water chillers.

Not Suitable for Water Scarce Areas

You will also go through a hard time using industrial water chillers in areas that do not have a sufficient water supply.

It is, therefore, not suitable for areas that do not have a sufficient supply of water.

How Much Do the Industrial Chillers Cost?

The cost of purchasing industrial water chillers will vary according to several factors.

High-quality industrial water chillers for high-efficiency applications will cost you more.

Industrial water chillers with high technological value will also cost more.

Generally, the overall cost of the industrial water chillers ranges from 30,000 to 90,000 US dollars.

How do you Maintain Industrial Water Chiller?

You should maintain your industrial water chillers regularly to increase and save on energy costs.

The maintenance process of the industrial water chillers involves cleaning the parts regularly.

Here, you will ensure that you clean all the parts including the tubes of the water chillers regularly.

To help you in cleaning, you must have the right cleaning schedule which will remind you of the right time for cleaning.

You must also check on the quality as well as the right levels of oil, water, and refrigerants in the industrial water chillers.

In case of a deterioration in the levels and quality of oil, you should consider refilling or replacing the reserves.

In addition to that, you need to inspect the machine regularly and check on the main parts in case of damages.

In case of a problem or imminent danger, you should consider repairing the parts or replacing them.

It will be easier if you install a program that will remind you of the right time for performing maintenance services.

Industrial water chiller maintenance

How Do Industrial Water Chillers Compare to Industrial Cooling Towers?

You will use both the industrial water chillers and industrial cooling towers to cool different devices in different applications.

Industrial cooling towers are devices that you will use to eliminate process heat from various applications and into the atmosphere.

Industrial water chillers are devices that use water as the main cooling agent that eliminates heat from different industrial systems.

They have varying working principles that they depend on to eliminate heat from different industrial applications.

You can also use the industrial cooling towers in collaboration with the industrial water chillers.

It can help in eliminating the heat from the process of water and releasing it into the atmosphere.

Industrial cooling tower

How Can you Test the Quality of an Industrial Water Chiller?

You must use industrial chillers that are of very high quality.

You can tell that an industrial water chiller is of high quality by doing a series of tests on them.

You must make sure that the industrial water chillers adhere to the right quality standards through quality tests.

There are three main tests that you can conduct on the industrial water chillers to test their quality.

Here are the main tests that you will perform on the industrial water chillers.

• Factory Acceptance Test
• Installation Qualification Test
• Operational Qualification Test

Do You Need a Mechanical Room for Industrial Water Chillers?

Yes, you must have a mechanical room where you will house the industrial water chillers.

It will protect the components of the industrial water from damage.

That is, especially from the destructive weather elements.

It is a quiet type of machine that you can comfortably accomo0odate within a mechanical room in the building.

Since it uses water as the main chilling agent, it does not require a constant supply of air to cool it off.

How Many Types of Refrigerants Do You Use in Industrial Water Chillers?

There are quite a several refrigerants that you can use in industrial water chillers.

Some of the refrigerants that you can use in industrial water chillers are:

• Chlorofluorocarbons (CFCs)
• Hydrochlorofluorocarbons (HFCs)
• Natural Refrigerants
• Halocarbons
• Freons

Industrial water chiller refrigerant filling

What are the New Technological Advancements in Industrial Water Chiller Systems?

Well, there are quite a several technological advancements that help in improving the efficiency of industrial water chillers.

These industrial advancements help in conserving the energy that industrial water chillers use.

Apart from that, the industrial water chillers have better technology that increases efficiency and cooling capacities.

Such technological advancements involve proper connectivity to improve energy flow and increase working efficiency.

In addition to that, there are variable speed drives with proper power control systems to improve efficiency.

Technological advancements that you should also look at include electronic commutated motors (ECMs).

These are types of condenser fan motors that help in eliminating the heat from the refrigerants faster.

It also comes with better and more adaptive control systems that allow you to control the machines better.

How Much Energy Does an Industrial Water Chiller Consume?

The amount of energy that the industrial water chillers use will vary according to the type of industrial water chillers.

In many cases, industrial water chillers use about 40% of the total energy requirements in industrial applications.

Huge industrial water chillers use a lot of energy in comparison to smaller industrial water chillers.

Modern technological advancements have modern devices that help in conserving energy.

You should consider using a machine that is capable of saving and conserving energy thus reducing the cost of operation.

Which Safety Features Do Industrial Water Chillers Have?

You should read all the instructions for operating the industrial water chillers before you operate the machine.

These instructions contain a set of rules of the DO’s and DON’Ts that you have to follow for safety purposes.

Apart from that, the machine comes with a system of sensors that is capable of detecting imminent danger.

The safety sensors will send warnings on the control display panel to alert you of imminent danger.

In addition to that, you can also depend on the sensors to automatically shut down the entire machine.

This happens when the machine is in great danger and further operations would cause great danger.

It also happens when you are in great danger of harm if the machine continues operating.

Industrial water chiller

Which Quality Standards Must Industrial Water Chillers Adhere to?

Quality is one of the most significant features that your industrial water chillers must have.

You should inspect the documents and ensure that the machine adheres to all the right quality standards.

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

• 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/ASHRAE 182 – 2008
• VDI Quality Standards such as VDI 4650-2

Which is the Best Material for Making an Industrial Water Chiller?

You will use different types of materials to make the industrial water chillers.

The main material that you will use in making the industrial water chillers is stainless steel.

Stainless steel is the best material for making an industrial water chiller.

This is because it has high tensile strength.

Apart from that, stainless steel is also a good conductor of heat that will help in the faster transfer of heat.

Can You Operate the Industrial Water Chiller from a Remote Location?

Yes, modern industrial water chillers have control panels with the latest technological advancements.

These control panels have installations that allow you to control the entire machine from a remote location.

It will also feed you with the right information on how the process works thus enabling proper monitoring mechanisms.

What is a Modular Chiller?

Modular chillers are types of industrial water chillers that have a plug-and-play concept for building multiple unit systems.

It is capable of reaching very high cooling capacities in applications that release a lot of heat.

The main types of modular chillers are:

· Modular Centralized Cooling Systems

These are single units with parallel connections to build and also increase the capacity of refrigeration.

· Cascade Cooling Systems

These involve single units that have been connected through series connections that help in reducing thermal loads.

It is the most energy-efficient type of modular chillers system that cools off the different systems in shorter periods.

Modular chiller

How do Industrial Water Chiller Manufacturers in China support OEM Clients?

Industrial water chillers manufacturers in China support OEM businesses by purchasing the raw materials for them.

Despite the small size of the original equipment manufacturers’ businesses, you are certain of getting very high-quality products.

Industrial water chiller manufacturers often purchase these raw materials and use them to make industrial water chillers.

These also include inspecting and buying quality equipment from third parties.

Also, they held in design work, testing, installation, and commissioning of the industrial chillers.

More importantly, industrial water chiller manufacturers in China offer competitive prices.

How does Industrial Air-Cooled Water Chiller compare to Water Cooled Water Chiller?

You will use both types of devices to help in the reduction of heat from different industrial applications.

Air-cooled water chillers are more suitable for cooling devices with air as the main chilling agent.

On the other hand, water-cooled water chillers depend on water as the main cooling agent.

Apart from that, you will house your water-cooled industrial water chillers in a mechanical room.

You will also use the water-cooled industrial water chillers in areas that have plenty of supply of water.

On the flip side, air-cooled industrial water chillers are best for areas that do not have plenty of water.

In such areas, you will depend on a blast of air that flows freely to help in cooling the system.

In many cases, you will install air-cooled water chillers outside the building with plenty of fresh air.

We would like to know your experience with the current chiller systems you are using.

In case you have any questions or inquiries, contact TopChiller for free consultations on industrial water chillers.