What Are the Advantages of Types of Industrial Chillers？

DIFFERENT TYPES OF CHILLERS FOR INDUSTRIAL AND COMMERCIAL USE

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Chiller systems are essential for temperature control and cooling in several industries. Choosing the right industrial chiller for process and space cooling can lower cooling costs, minimize downtime, and improve operational efficiency.

This article will cover the different types of chillers for commercial and industrial applications and the pros and cons of each. The aim is to help you make an informed buying decision.

Types of Industrial Chillers (Based on Condenser Type)

The three major types of industrial chillers in use today are air-cooled chillers, water-cooled chillers, and evaporative condensed chillers. Let&#;s take a closer look at all three:

Water-Cooled Chillers

The most common types of water chillers use water from an external tower to cool the gaseous refrigerant in the condenser. After expelling its heat, the refrigerant undergoes a phase change into a liquid and is recirculated into the system.

The Pros

• Water-cooled chillers are generally more efficient than air-cooled chillers
• They have a quieter operation than air-cooled systems
• They are suitable for both small-scale and commercial-scale cooling
• Portable solutions are available for facilities with space constraints

The Cons

• Water-cooled chillers can be costly to install and maintain due to the additional cooling water tower, tanks, and water pump
• Since they require a constant supply of water for cooling, they might not be suitable for locations with water shortages or restrictions
• Water-cooled systems require periodic condenser water treatment to prevent the formation of mineral deposits in the system. 

Explore portable, stationary, central, and custom water-cooled chillers from Cold Shot Chillers here.

Air-Cooled Chillers

Air-cooled chillers use ambient air to reject heat from the refrigerant in the condenser before condensation and recirculation. Additionally, air fans attached to the unit help speed up the cooling process.

Air-cooled chillers are suitable for applications where the discharged heat will not be an issue, as they tend to produce considerable warmth at the site.

The Pros

• Portable solutions are available for facilities with space constraints
• Air-cooled chillers are available for small-scale and commercial-scale cooling depending on sizing and chiller capacity
• They are cheaper to install and maintain than water-cooled systems
• The heat from the chiller can warm the facility during cold periods, providing additional cost and power savings. 

The Cons

• Air-cooled chillers use cooling fans that produce some level of noise
• The life expectancy of an air-cooled chiller can be less than that of a water-cooled chiller

Comparison Between Air-cooled & Water-cooled Chillers

While the components of air-cooled and water-cooled chillers are mostly the same (condenser, expansion valve, evaporator, and compressor), the main difference is how the refrigerant is cooled.

In an air-cooled chiller, hot refrigerant entering the condenser is exposed to atmospheric air, rejecting the heat before it condenses to its liquid state. On the other hand, in a water-cooled chiller, hot refrigerant gas is sent to a water-cooled heat exchanger or condenser, and the refrigerant is cooled using water from a cooling tower. For a better understanding, learn how cooling towers and chillers work together.

Classification of Chillers (Based on Mode of Operation)

Industrial chillers can be further grouped as &#;vapor compression&#; or &#;vapor absorption&#; types based on how the refrigerant is transported within the system. Take a closer look at how a chiller works in these different system types.

Vapor Compressor Chillers

Vapor compressor chillers use a compressor to pump refrigerant, which extracts unwanted heat from a process. The components of the system are the same as in the absorption type &#; we have an evaporator, a condenser, and an expansion unit. However, there is no absorbent medium in the unit.

Vapor Absorption Chillers

Unlike vapor compressor systems, vapor absorption chillers use a heat source to transport the refrigerant around the system for cooling. The components of the system are the same as in vapor compressor-type chillers, but in place of the compressor, there is an absorber, a pump, and a generator.

The heat source can be heated by water or steam; the refrigerant can be a low Global Warming Potential (GWP) type like R-134a or Rze, and the absorption medium can be a solution of Lithium Bromide or ammonia. The heated water or steam helps regenerate the adsorption solution.

Screw Chiller vs. Centrifugal Chiller

Centrifugal chillers are dependable vapor compression cycle chillers ideal for medium to large-scale cooling operations (from 150 &#; tons of refrigeration). They consist of the usual evaporator, compressor, condenser, and expansion device set-up but with additional rotating impellers, which compress the refrigerant and transport it around the system. 

Screw Chillers are vapor compressor chillers that use a screw compressor to transport the coolant through the system. Some key benefits are compact installation, quiet operation, lower maintenance costs, and high energy efficiency. They are also ideal for high-rise buildings.

Both chiller types offer efficient cooling for facilities. However, Cold Shot Chillers recommends using centrifugal chillers for high-volume cooling and screw chillers for dependable operation in facilities with space constraints. To better determine your needs, use our chiller sizing calculator.

Types of Industrial Chillers (Based on Application Type)

Food & Beverage Chillers

Maintaining optimal temperatures for food and beverage products is critical to ensure their safety and quality. Food and beverage chillers are used in the industry to achieve this, whether it&#;s to cool liquids like milk or juice or to keep food products fresh. Different types of chillers are available, including air-cooled and water-cooled units, with the size of the chiller depending on the amount of product being cooled and temperature requirements.

Medical Chillers

Medical chillers designed for healthcare applications play a vital role in maintaining optimal temperature levels, particularly when it comes to sensitive medical equipment like MRI machines and CT scanners. With precise temperature control, these chillers ensure consistent performance and prevent overheating, which can impair equipment and patient safety. Chillers also help maintain sterile environments by precisely controlling humidity levels.

HVAC Chillers

HVAC chillers are critical components of various industrial and commercial applications, including hospitals, data centers, and manufacturing plants. These chillers help to cool water or other fluids to provide air conditioning or process cooling. These chillers can range in size from small units that fit under a desk to large systems requiring an entire room. Choosing an appropriate chiller size and type can help businesses improve efficiency and reduce energy costs while extending the life of their HVAC mechanical systems.

Metal Finishing Chillers

Industrial chillers for metal finishing ensure high-quality metal plating and chemical processes. The precise control of temperature provided by these chillers is necessary to avoid corrosion, pitting, and other defects resulting from incorrect temperature regulation. Therefore, when selecting an industrial chiller for metal finishing, it&#;s important to consider factors such as the size of the application, the required temperature range, and the type of chemicals being used.

Industrial Chillers

Industrial chillers are applicable in a wide range of commercial and industrial operations where they can be used to cool large-scale machinery and equipment to ensure optimal performance. Different industrial chillers are available, including air-cooled, water-cooled, and evaporative cooling systems. With proper planning and adequate maintenance, industrial chillers can provide reliable cooling for several years.

Plastic Processing Chillers

Maintaining precise temperature control is crucial in the plastics industry, which is why chiller systems play an essential role. The right chiller system can improve productivity and enhance product quality while reducing energy costs. Air-cooled and water-cooled chillers are available to meet various application-specific requirements.

Cold Shot Chillers Has the Best Industrial Chillers for Your Application

For over 30 years, Cold Shot Chillers has manufactured the best industrial chiller systems to meet the process cooling needs in industrial and commercial applications nationwide.

For more information, please visit How Does a Water Cooled Chiller Work.

Cold Shot Chillers offers ruggedly dependable and efficient water-cooled and air-cooled industrial chillers with close tolerances for any application as well as parts and accessories. For inquiries, please contact us online today or call us at 1.800.473..

What is a chiller? 

Industrial chillers utilize refrigeration technology to remove heat from equipment, process fluids, and manufacturing areas to maintain appropriate temperatures for the environments and applications in which they are deployed. They are commonly used in sectors involving injection molding, machine tooling, paper processing, metal plating, food and beverage, pharmaceuticals, research labs and other industrial categories that call for precise operating temperatures. Chillers offer efficient thermo control to remove excess heat.

What do chillers do and what are the biggest benefits of an industrial chiller?

A water chiller prevents equipment from overheating, which can extend its lifespan and reduce production downtime. In some ways, it could be considered part of predictive maintenance. It may also be used to cool process fluids like various chemicals and oils, which can reach dangerously high temperatures in manufacturing environments and possibly cause fires. A water chiller will help protect workers, equipment and property by maintaining appropriate ambient temperature for the application. Removing the variables related to temperature makes process development and optimization easier while maintaining the highest possible quality.

What kinds of chillers are available?

There are several kinds of chillers available, and two of the most commonly used are water-cooled and air-cooled chillers. In a water-cooled chiller, chilled water runs through a piping system that absorbs heat from the air. An air-cooled chiller uses fans and refrigerant to transfer heat from a process to the outside.

SMC Corporation&#;s HRS, HRS-R, HRSE compact recirculating chillers are designed for a wide range of single-point applications in both industrial and technology settings. Each unit&#;s design is powerful enough for the factory, while also being ergonomic and compact for lab installations. Coolant can be either heated or cooled within the set temperature range. Available with a choice of eight cooling capacities, air or water cooled refrigerant, global power supply options, and US stock availability, SMC chillers are a reliable and accessible choice for thermo cooling.

The SMC HRS Series is a floor-mounted series of temperature control equipment. A coolant circuit runs between the chiller and the heat source, drawing off the heat. That heat is then removed from the coolant by a refrigeration circuit. Heat can be generated by industrial processes or machinery running. The HRR Series operates in a similar manner but is packaged to mount on a standard 19-inch rack, which frees up floor or tabletop space and can also allow for stacking and mobility.

The HRS and HRR Series are well known for reliable service, tight temperature control, compact design, easy operability, strong status reporting, and a wide range of capacities. While not completely unique in the marketplace, the HRR rack mount style is very uncommon. SMC&#;s 6 capacities and water or air cooling options are one of the best offerings in the market.

Chiller Evaluation Program

SMC has a trial program that allows customers to evaluate chillers for up to 30 days. Chillers can be a significant investment and the trial program allows you to test the product with your application before committing to a purchase.

Program Features

• Validate your cooling process
• Evaluate our chiller before purchase
• Variety of styles and capacities
• Over 70 chillers available
• Evaluation period up to 30 days

Success Stories

Goal: Switch from City Water-sourced Cooling Systems

Many end-users of the OEM&#;s gable-top packaging machines wanted the option to change from city water-sourced cooling systems. An SMC Trial Chiller was introduced. The OEM&#;s end-users operate the gable-top carton packers in ambient temperatures - from high (adjacent to milk pasteurizers) to chill (juice fillers), so the engineers had to simulate many scenarios for cooling capacity.

The cartons start as flats then folded into rectangles, next the bottoms are heat sealed, then chilled to set the seal. The chiller must perform in various ambient temp. filling facilities to cool the cooling plate to set the carton seal in < 1 sec.

The engineers embraced the evaluation program and tested a HRS030-R in their labs to simulate many conditions their end-users would operate their fillers. 

Goal: Keep an Optical Polishing Machine from Overheating and Halting Production

The electromagnetic wheel overheating will shut down the lens polisher and affect the MF fluid&#;s viscosity; Lytron&#;s chiller was underperforming. Zach and Doug called John to help size the evaluation chiller (HRS050); the OEM installed it on their contract manufacturing side of the company with great results during the evaluation period. The contract manufacturing side purchased the HRS050 and replaced all their old units.

Goal: Source a Higher Cooling Capacity Rack Mount Chiller 

The OEM builds a variety of ultrasonic welders and requires the higher cooling capacity available with HRR. The OEM leveraged the Chiller Evaluation Program to sample a properly sized HRR for testing. After months of in-house operation, the OEM was satisfied and ordered two units. The HRR for the first ultrasonic welder performed to specification but the second HRR for another welding unit kept indicating an &#;alarm 21&#; fault causing an emergency shut down on the welder. After initial inspection, it was believed the cause was a faulty solder joint on the control board, but some chiller engineers were skeptical this was the problem. Because the OEM had to ship in four days or else pay penalties to the end-user, this problem needed to be solved ASAP.

SMC staff diagnosed the root cause as the control display board not the solder joint and after quick replacement, the repaired HRR was approved for reshipping. The OEM was highly impressed with the level of service and has been acquired by Emerson, parent of ACSO/Numatics, and their engineers prefer to collaborate and specify SMC components over their new &#;in-house&#; brands.

Take control of your cooling needs and ensure your equipment operates at peak performance with SMC&#;s advanced chiller solutions. Whether you're looking to prevent overheating, extend equipment lifespan, or optimize your processes, our HRS and HRR Series chillers deliver unmatched reliability and efficiency. Don't miss out on the opportunity to experience the benefits firsthand. Join our trial program today and evaluate the perfect chiller for your application, risk-free for up to 30 days. Contact us at 1-888-600- to learn more and schedule your trial. Transform your temperature control with SMC &#; where precision meets reliability.