The importance of portable industrial chillers

Industrial chillers are big machines meant for removing heat from a liquid. They are used widely for cooling of products, various mechanism and even machinery. They help in preventing the equipments from overheating and causing malfunctions to itself and to the company as well. Industrial chillers comprise of four types of compressors: the reciprocating, centrifugal, screw and scroll. These compressors produce a cooling effect through a vapor-compression method. They also come in two kinds of chillers: Water and Air cooled chillers. Water cooled chillers are ideal for indoor installation and operation. It uses cooling towers to release heat into the atmosphere. Air cooled chillers on the other hand, are ideal for outdoor installation and operation. They release the heat into the atmosphere through the condenser coils that are in the machine itself. There’s no need for cooling towers anymore.

Industrial chillers are big machines with big functionalities but what about the small things that need chillers too? What about the small applications, equipments or processes that need a close control? What happens then?

For these, there are portable industrial chillers for the job. They are smaller compared to the actual machines and they can be used anywhere, without being limited. Examples of processes that need close control is the injection molding or the processes within a glass blowing industry. Portable process chillers can be moved to provide close control over these processes to ensure nothing goes wrong.

Portable industrial chillers are also best for places where available space is limited. When you’ve got small-scale operations, portable industrial chillers are the way to go.

Options for Used chillers

Industrial chillers age after quite some time.  Its efficiency and effectiveness when it comes to performance begins to falter especially when these chillers have been used over long periods of time and carrying heavy loads. Despite the efforts done in chiller maintenance, a chiller also reaches a stage where a replacement is needed.

Used chiller replacement isn’t easy because there are a hundred different options to choose from with varied capabilities and specifications. Looking for a new chiller and reviewing the characteristics of each one takes a lot of time and intense concentration if you want to get the value for your money. But keep in mind that in looking for new process chillers, it is important to know what it can do for you.

Aside from replacement, conversion is also another option for used chillers. Conversion is modifying the type of refrigerant that the chiller is designed to use. However, this could get complicated because you need to find the original design conditions of the used chiller to be able to help the manufacturer decide which refrigerant to switch to. Energy efficiency of industrial chillers when conversion is done gets better on a KW per ton basis.

Another option is retrofit which is the process of replacing certain parts of the used chiller but keeping the existing condenser and evaporator heat exchangers. The motor, compressor, starter and control panel are changed. This is recommended only if there’s no easy access to a chiller area.

When used chillers falter, replacement isn’t the only solution you can run to. Whichever option you choose, always seek professional help as they know and understand chillers better.

Are process chillers useful?

Process chillers put simply provide cooling for processes or applications in certain industries. Industrial chillers often have process cooling methods to help them with the applications they’re running. Process chillers are composed of a compressor, condenser, evaporator, pipes, high pressure refrigerant relief valves and pumps. They are designed to stand the roughest environments and toughest conditions there is. These chillers take away heat and supply a consistent desired temperature throughout the day or the entire processing time. With this, the efficiency of the processes is improved.

Here are some of the industries that use process chillers:

Printing Industry- Process chillers are used to control the temperature in presses and rollers which results in efficiency and quality with lower costs because there’s lesser stretching and bleeding upon printing.

Baking – Process water chillers are used in the mixing process because the chilled water from the chiller allows longer mixing times and thus improves the final quality of the ingredients being mixed.

Plastic Production – Process chillers are used in regulating temperatures during injection molding and blow molding.

Food – Process chillers are used to cool processes like vegetable processing, confectionery making and chocolate manufacturing.

These are only some of the industries that use process chillers. A lot more out there are turning to these things to take advantage of its benefits. These industries include, but not limited to, boat and airplane manufacturing, skating rinks, dry cleaners, chemical industries, pharmaceutical industries and metal finishers. Process chillers have proven to be beneficial and industries will continue to use them.

When is it time for chiller repair?

Operating used chillers call for more attention that new ones, naturally. A refrigerator at home is an example. Like any other thing, they also age and the wear and tear may be visible depending on how it is handled. Chiller maintenance also plays a great role in the efficiency of used chillers and its ability to maximize its optimum potential. When all else fails, chiller replacement for process chillers is the last step to be considered. But we all know that chillers aren’t small, inexpensive things. Chillers cost a lot of money thus replacement shouldn’t be done in haste. There are times when the only thing needed to get your process chillers running again is repair.

When can you tell if your used chiller calls for a repair?

- An excess vibration is a sign that there is an extreme wear on the bearings of the chiller. If this is the case, a technician who specializes on chillers should be asked to remove and check the bearings.

- An increase in Refrigerant approach temperature is one of the first signs that a chiller is not operating well. In these cases, a repair is likely needed. A technician should be contacted to check and investigate the problem that may have caused this.

- An obvious refrigerant leak is a sign that the chiller is in need of a repair. Even if the leak isn’t obvious but the refrigerant level is low, it’s still a cause for alarm. Chiller maintenance should be called for to avoid a loss in refrigerant and to avoid inefficiencies.

Should you replace your industrial chillers?

Chillers are big ticket items which mean they cost more than other equipments. Industrial chillers are examples of this. The purchase of an industrial chiller is a big cost to the company’s finances thus taking good care of it should be done properly and regularly. Minor defects could bring down the entire system’s maximum efficiency and when that happens, you’re paying more for a lesser performance. Because industrial chillers are expensive, replacing them should be done with utmost care and thorough decision making.

Here are some tips and tricks on how to evaluate your used chillers to see if they need any replacement:

• The age of the used chiller should be taken into consideration. For air cooled chillers, typical life span is about 12 years while it can be more than 20 years for water cooled chillers. If they chiller’s age is near or beyond these numbers, a replacement is better than repair.
• The major repairs done on the chillers should be given much weight. It may be cost effective to buy a new one rather than paying for repair over and over.
• The noise level should be checked. If you need chillers that aren’t noisy, the new chillers have lower decibel ratings compared to that of before.
• The efficiency rating of the chiller should also be checked. New chillers nowadays have improved efficiency ratings.
• The size of the chiller is also important especially for limited places. There are new chillers released that are small, compact and just as powerful and efficient than big chillers.

Before buying a new replacement, ponder over the things mentioned above. They might come in handy so you can end up in a decision you won’t regret.

The truth about chiller replacements

Industrial chillers are great equipments that bring in a lot of great benefits to industries. But they’re also expensive. In fact, they may be the most expensive equipment in other companies.  This is the reason why it is important to observe chiller maintenance and make sure that chillers aren’t abused. Chillers need to be taken cared of if industries want them to perform and serve them for a long period of time. But all good things must come to an end. However with industrial chillers, caution and thorough decision should be done before making a choice.

The biggest mistake in chiller usage is thinking that just because chillers, no matter how used, are still operating mean that they are still ok. Used chillers are still operating but not efficiently anymore and the overall cost for electricity charges may be more than the initial cost of actually buying a new one. However, one must think of all the factors before getting a replacement for used chillers.

A chiller’s condition is important and how old it already is. Changes have been made over the years and if the chiller started operating 10 years ago with a specific set of load, chances are they have changed as well. This may have caused an oversizing of the chiller. You can do a review of the load profile of your current building and re-evaluate the maximum cooling load that the chiller needs to meet. If it can’t be met, it’s a good sign for the chillers to be replaced but it still needs to be evaluated thoroughly.

How do you keep chiller efficiency high?

Since industrial chillers are greatly needed for certain industries, it is important to keep them effectively and efficiently performing at all times. Despite what type of industrial chiller is used, only one thing remains certain: regular maintenance for chillers should be observed.

Chiller maintenance is an important part of a chiller’s life. In order to keep your chiller’s efficiency high, you have to take time to check it regularly. You need to check the tubes, the controls, refrigerant charge optimization and regular oil changes.

In cleaning the tubes, you need to inspect the heat exchanger tubes and flow devices. A tube’s condition will determine how to clean the tubes in the future and it also tells you if the water used is good for the tubes or not. Cleaning the tubes help greatly in the efficiency of used chillers.

Refrigerant charge is important in optimizing used chillers’ performance and energy efficiency. Too much of it can cause a carryover which can cause a reduced capacity and excess power consumption among other damages. Not enough supply can also lead to trouble. This is why it is important for the refrigerant charge to be just enough.

Oil is also critical in chiller efficiency. It is important to do an oil analysis once a year. You should also do oil and filter change after a year. Particles in the oil tell you what type of wear problem is happening inside the chiller. The oil level must also be observed closely.

Like any other equipments, regular checkups and maintenance is needed to keep chiller efficiency as high as possible.

How does a air cooled chiller differ from a water cooled chiller?

Industrial chillers are of top priority in most industries and companies worldwide. These chillers help cool the equipments and the environment as well. They help maintain the effectivity of the equipments at hand. Industrial chillers come in different variations and design but still offering the same functionality. They work towards the same purpose but the difference in the way they work help companies choose which one fits the nature of their business.

Industrial chillers can either cool by air or cool by water and they have the same parts. They each have an evaporator, compressor, expansion valve and a condenser. They also have the same functionalities but the difference lies in how they refrigerate fluids which makes a great difference especially for most industries.

An air cooled chiller rejects or gives out heat into the air. They are less efficient when it comes to energy but they are also less expensive to purchase and maintain. This is the reason why air cooled chillers are being widely used in most industries.

A water cooled chiller on the other hand, also gives up heat. However, it gives up heat into another water source instead of into the air. Water cooled chillers are ideal and practical for industries that have cooling plants or a water source ready.

These chillers come in different designs to help industries tend to their needs in the most efficient of ways. Through this, they are given options and can maximize the equipments they have at hand for the improvement of their overall progress.

What are the types of condensers?

We all know that industrial chillers are beneficial and help industries cool the necessary equipments. We all know that they are high-priced items and proper chiller maintenance should be observed if you posses one to maximize its life span. Otherwise, you’re risking of cutting off its efficiency and eventually its life. It is also important to know all that we can about chillers to better equip ourselves.

While other articles are talking about the different types of chillers: from air cooled chillers to water cooled chillers, this article talks about just one part of both types of chiller. Before getting to this particular part, the refrigerant must travel across different tubes and mechanisms that aid in the whole process. After which it ends up in this special place: the condenser.

The condenser is where the refrigerant gives off heat energy into either a water source or air. Most chillers use air cooled or water cooled condensers to aid with this process:

•    Air cooled condenser

An air cooled condenser is a copper tubing coil that has aluminum fins and condenser fans. They are an essential part of a chiller because this is where the refrigerant throws out heat directly into the air.

•    Water cooled condenser

Water cooled condensers have shell and tubes for heat exchangers that have condenser water running through them. The condenser water flow must have the same flow velocity as that of the evaporator.

Industrial chillers or any type of chillers have condensers. They may differ in the process and design but they were created for one purpose only: to remove heat and give that cooling effect needed.

How to buy chillers and what to consider

Going shopping for chillers is not as easy as it looks. You need to be in the know so you can make the right choice and not end up with something that can only complicate things instead of helping.

When you’re out buying your very first industrial chiller, there are a few things to consider such as materials, components, efficiency and operation. By taking them into consideration, you are assured that you’re not only getting a good chiller but you’re also getting your money’s worth. Let’s take them one by one.

The first factor you need to check out in buying process chillers is the materials used in the production. Stainless steel is the best choice for chillers nowadays.

To avoid future trouble with parts, make sure that the components of your chosen chiller whether it be a water cooled chiller or an air cooled chiller are standard components that are available in other major wholesalers and not just manufacturers.

Of course, industrial chillers are of no use if they can’t deliver efficiency. You have to compare the money spent on the chiller and the money you can save on energy over a long period of time.

Chillers must be user-friendly. The controls must be easy to read and easy to use. This is essential especially to first-time users. Any complications might lead to misuse and destruction of the chiller.

Choose a chiller that have components place for easy access for inspection and replacements if necessary. Small-compact units aren’t that advisable because chiller maintenance tends to be a hassle, having to take the chiller apart for inspection or any other service.

Chillers come with a warranty of up to 5 years for new ones. Check out for how long the warranty is for your chosen chiller before you make it to the cashier.

How process chillers can save water

How do industrial chillers save water? Well, with global warming becoming more and more apparent, a little effort in saving our environment goes a very long way. One natural resource in particular that we’re nearly running out of is water. If we don’t take care of it, we’ll lose it. Thus, saving water is of primary importance right now.

A large amount of water is used in different industrial purposes all over the world. Because of this and the desperate pleas for our environment’s survival, industries are now looking for ways to cut back the waste.

An example of an industry that uses a lot of water is a hospital. Sterilization is a key aspect in a hospital’s day to day activities. Instruments and equipments must be sterilized to ensure safety and health. However, large amounts of water are needed to cool the sterilizer and these amounts usually end up in waste after used.

Instead of wasting too much water on that, you can use process chillers. These chillers take hot water from the condensers and vacuum pump. They then cool it down and pump it right back to the sterilizer. Process chillers also help keep the cycling time of sterilizers constant regardless of different weather conditions. If your chillers have large buffer tanks, there are no negative effects even if there’s an extreme change in temperature. Switching to industrial chillers prove to save a lot of money and water at the same time. With the right chiller maintenance, your chillers will last longer than you thought.

Chiller Efficiency and Maintenance

If your company owns one of those industrial chillers to help maintain various equipments that may be damaged from too much heat, then you’d probably know that chiller maintenance don’t come easy.

A chiller can only be beneficial if its efficiency is at its maximum or remain to be unaffected despite several factors.

A chiller’ efficiency is measured by the amount of energy it needs or it takes to produce a ton of cooling and is usually expressed as kw/ton. All types of chillers including air cooled chillers and water cooled chillers have certain efficiency established before being released out in the market. However, there are a lot of factors that can affect it which can result to poor efficiency and higher operating costs.

An industrial chiller can have an operator to better keep track of the activities. The operators are known by a few titles: Stationary Engineer, HVAC engineer or service technician. Nevertheless, they perform the same job: they watch over the chillers. Chiller operation includes collecting and logging data from different estimates and controls the meters near or on the chiller. There are also service contractors whose expertise is the equipment repair. They are the ones you must call when you need major repairs.

There are three types of chiller maintenance:

Water chemistry – keeps the proper balance and minimizes the effects of corrosion, and debris fouling.Mechanical Maintenance – includes adequate liquid refrigerant, proper lubrication and a series of oil levels and pump curve tests.Operational Procedures – includes calibration of gauges and meters, oil analysis and other different tests that checks the operation process.

Chillers must be maintained and kept well for a longer lifespan. They don’t come cheap so taking care of them is worth the extra years they give as service before they break down.

Chiller Threats

In big industries, chillers use up almost fifty percent of its entire electricity consumption, making them high-maintenance equipment. Because of this, proper maintenance for industrial chillers or any chiller for that matter should be a priority and should be something that is consistently being done.

Poor operating practices cuts down the chiller’s life as well as decreasing its efficiency. These practices include but are not limited to trying to force a chiller to do something that it wasn’t designed to do. You have to understand what your chillers are meant to do. You have to get to know your process chillers or other types of chillers. An important note with these practices is that the consequences are unnoticeable at first. Chillers continue to act normal but time will come when it gives in and breaks down faster than it should.

Chiller maintenance shouldn’t be taken lightly especially for equipment such as this. Good maintenance is essential in keeping chillers in top condition. A brand new air cooled chiller can carry a particular amount of load. Over time, that load decreases gradually. However, if maintenance is ignored then that decrease will happen faster than it should.

Chillers have cooling towers that assist in their efficient operation. They allow chillers to operate efficiently to their maximum potential. It is essential that these cooling towers are kept in top shape because a slight decrease in its performance will have a major impact on the chillers.

A chiller should be properly sized for an efficient operation. For example you have a new air conditioning chiller and the size of the load is sufficient for it to run smoothly. However, changes are made such as new windows or new lighting systems. This decreases the load for chillers and as a result, decreases its efficiency. You have to keep track of this and make sure that the balance is maintained.

Chillers have helped humanity in more ways than one especially in big industries. Therefore keeping them safe and treating them well is just right.

How Chillers Work

In every water cooled chiller, the liquid is separated from the refrigerant by sealed tubes or coils. Water is then passed through a series of sealed tubes in and around a compressed refrigerant of ammonia or Freon. The heat from the warmer water is passed through the metal sealing tubes and into the gas of the refrigerant which is then sucked off through the vessel by a compressor.

Air cooled chillers range in different sizes from the common cold drinking fountain to large industrial chillers that can accommodate thousands of gallons of liquid. Regardless of the size, water chillers all have the same function, which is to remove unwanted heat and cool down the liquid to a desired temperature. After removing the unwanted heat, the cooled chiller will discharge it elsewhere.

The refrigerant enters the heat exchanger in the form of a liquid and it comes in contact with the sealed tubes that contain the water and while this happens, it flashes into a gas. The flashing of the refrigerant happens when the heat is exchanged from the warmer water through the metal tubes and into the recirculating chiller. The heat, which is now in gas form, gets carried away by the suction of the compressor.

Through the operation of a fan, the machine’s condenser releases heat that was captured by the gas into the air. The gas then turns back into a liquid or condenses as it cools and then exits the condenser. The liquid refrigerant is then forced back into the heat exchanger vessel to perform the same work of removing heat from the warm water. This is the same process that is used on a refrigerator.

Always remember that proper maintenance on the chiller is needed to lengthen the appliance’s lifespan.

How Some Water Chillers Are Used

Chillers, sometimes called water cooled chillers, is a machine that is used to cool large facilities such as industrial, commercial and institutional places. A water cooled chiller uses heat from liquid by means of a vapor compression cycle. It is generally made up of a compressor, a condenser, an evaporator and metering devices.

Air cooled chillers and other industrial chillers circulate roughly four hundred tons of water at a time. Chiller such as this are expensive and large, so they are kept on the sides of buildings or on rooftops. Often, they are used in lieu of evaporative cooling towers, since they allow refrigerant chemicals to come into direct contact with cooled water.

Compressors in air cooled water chillers have different compression methods with its own benefits and disadvantages. There are four compression techniques: centrifugal compression, screw-driven compression, reciprocating compression and scroll compression.

Scroll compression is small in size and cost effective while centrifugal compression is energy efficient. The compressor is a key aspect of every water chilling device and selecting the right type of compressor is important if you want your machine to have optimum performance. Instead of pumping in water city, water chillers can let you save lots of money in a year because they can pump water in a closed circuit. This is why they are also called recirculating chillers. Doing this reduces overall water usage and provides an ecologically friendly way to cool water.

Chillers are also used in evening out the temperature in aquariums and also in manufacturing circumstances where water has to be at a fairly precise temperature so that finicky equipment or products can be used and produced properly. Water chillers have also become important in some people's everyday life and proper maintenance can help you save money in the end.

Purchasing a Used Industrial Chiller

If you're a person interested in purchasing a used chiller for an expansion or probably a renovation, you've made the right decision. Industrial chillers are available in high quality models because of factors like remodeling and liquidations. Chiller models with short runtimes are increasingly available on the market.

When it comes to buying used chillers from a surplus buyer, the price and range of quality are usually reliable. A few categories like the manufacturing date, price range and usage capacity are very common labels that a potential buyer should consider before purchasing the chiller.

Various providers offer air cooled chillers, water cooled chillers and a wide range of other semi conductor equipments. When buying second hand chillers, make sure you pick a company that can provide you with a high quality chiller. There are actually lots of advantages when you buy a used chiller. The major advantage is that it saves time and money. Previous use of the unit ensures us that the equipment is working well. There are lots of shops that offer to buy-and-sell your used chiller equipment.

Used chillers are available with different specifications. When buying one, make sure that there's a label stating the chiller type together with a description of the item, date of manufacturing and selling. It should also consist the approximate shipping weight, original list price and power supply. A brand new, high quality used water chiller would cost around $5,000 in its list price but would be available for you in the sell price of $1,500.

Purchasing new and expensive chillers isn't necessary. Used chillers that are well taken care of are not only light on the wallet, but they also serve its purpose.