When it comes to cooling applications in industrial settings many businesses are turning to industrial glycol chillers and for good reason. An industrial glycol chiller is unique in the way that it is designed to operate and work in low temperature scenarios. An industrial water chiller has the tendency to freeze in cold environments, but the industrial glycol chiller uses a glycol based coolant that has a freezing point well below zero. This means it has the ability to perform cooling applications when temperatures dip well below zero, making it perfect for industries such as food processing, which has cold storage requirements. Furthermore, industrial glycol chillers allow for great heat transfer efficiency. The glycol mixture in the chiller absorbs heat and releases it in a sufficient manner which ensures that industrial equipment/production processes are kept to the desired temperatures. This operational efficiency not only boosts the end product quality but also saves considerable energy, thus, operational costs.
There are several key industries that rely on industrial glycol chillers, one of which is the food and beverage industry.
In food processing plants, industrial glycol chillers are used to cool food ingredients while food products are in storage to maintain freshness. In dairy processing, spoilage is avoided by maintaining milk and cheese at proper temperatures. The pharmaceutical industry uses industrial glycol chillers too. It is necessary for the production and transportation of medications and vaccines to provide the necessary consistent cooling to keep them effective. The industrial glycol chillers offer the required low-temperature cooling for the storage and transportation of these sensitive products. The plastic manufacturing industry also benefits from industrial glycol chillers. During extrusion and molding of plastics, excess heat is generated and the glycol chillers cool the machinery to prevent overheating and provide consistent plastic products. In the HVAC industry, industrial glycol chillers are used to control the temperatures of heating and cooling systems in large commercial buildings.
The industrial glycol chiller offers stable and efficient cooling due to the precise design of its components and the order in which these components function.
The refrigeration system is made up of four essential parts: the compressor, condenser, evaporator, and expansion valve. The refrigerant gas rises in both pressure and temperature. The condenser is next, where the refrigerant gas loses heat, and it turns back into a liquefied state. Once liquefied, the refrigerant flows into the expansion valve where it loses pressure and temperature. The evaporator is next where the refrigerant absorbs the heat from the glycol coolant. The glycol is then cooled, and it is continuously circulated in the industrial equipment and processes to absorb heat. The cooled glycol is then returned to the evaporator to undergo another cooling procedure. The steady cycle helps the glycol chiller to maintain the temperature. In addition to this, modern industrial glycol chillers come with built in control systems which manage the system pressure and the temperature of the flowing glycol. This closes the loop on the system to ensure efficient cooling and to eliminate any temperature changes.
First and foremost, the cooling capacity of the chiller is the most critical consideration when selecting an industrial glycol chiller.
The cooling capability of an industrial process or equipment depends on how well the heat load is managed. If an industrial glycol chiller is permanently undersized, it will not cool sufficiently, creating the risk of overheating. Conversely, oversized chillers will chill more than necessary, wasting energy. The third consideration is the type of glycol. Ethylene glycol and propylene glycol have different characteristics, and Ethylene glycol is far more efficient in heat transfer. However, the toxicity of Ethylene glycol is a detriment while the non-toxicity of propylene glycol is an asset, especially in the food and pharmaceutical industries. The operating temperature is another important factor. Those in the market for an industrial glycol chiller must ensure the unit can handle temperature variations for the specific application. In addition, the chiller’s size, installation considerations, and overall industrial setup compatibility must be taken into account. Last are energy efficiency and maintenance. An energy efficient chiller will negatively affect the operational costs while a chiller with low maintenance needs will keep the operational downtime more predictable.
Regular maintenance is important in order to maximize the life of an industrial glycol chiller as well as maintain its consistent performance in the following years. First, maintenance consists of regularly checking and replacing the glycol coolant. Glycol may become inefficient as a coolant if it is contaminated with dirt, rust, and other impurities, which can harm the industrial chiller. To combat this, it is best to test the glycol’s concentration and quality bi-annually and replace it if necessary. The second maintenance task involves the regular cleaning of the chiller’s evaporator and condenser coils. When dust, dirt, and debris accumulate on the coils, they restrict airflow, which hinders heat exchange within the coils. To mitigate this, lightly brushing or using compressed air to clean the coils on a quarterly basis is best. The third maintenance strategy focuses on leak detection within the refrigeration system. Losing refrigerants through leaks in refrigerant lines results in less cooling power for the industrial glycol chiller. Implementing leak detection with a refrigerant detector is a great pro-active strategy in tracking and repairing leaks. Lastly, in order to combat the development of wear and friction, the compression and fan motors should be lubricated on a regular basis.
Last of all don’t forget to keep a history of all the maintenance work done, which will aid in the analysis of service dates, repairs, and part changes made on the industrial glycol chiller. This will help determine the performance of the industrial glycol chiller and look out for issues that could be avoided.
Long-term use of industrial glycol chiller for cooling applications will lead to remarkable value. The foremost value is the reduction in use of power. The industrial glycol chiller is made to be energy efficient, due to the use of advanced technology that reduces energy use. For instance, variable speed compressors adjust their speed based on the cooling demand which helps in eliminating energy waste during low heat loads. This will help in reducing the electric bill compared to other inefficient cooling systems. Less maintenance is also a value. The industrial glycol chiller is robust which eliminates the need for excess maintenance, which helps in reducing the maintenance service cost. Unlike other cooling equipment that has excess part replacement and repairs, the industrial glycol chiller will run for many years with just regular maintenance. This will reduce the replacement part costs and excess maintenance service costs. Industrial glycol chiller also prevents product loss.
In the food and pharmaceutical industries, keeping products fresh and effective depends on specific cooling products. The industrial glycol chiller maintains stable cooling. This minimizes the opportunity costs related to spoiled products. Additionally, the industrial glycol chiller can last a long time, up to 15 years plus. This long lifespan, combined with the cooling equipment's proper maintenance, minimizes the overhead costs associated with the replacement and installation of new cooling equipment, chillers, and all the associated costs.
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