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What to Look for in an Industrial Chiller

On first thought, choosing an industrial chiller may not seem like that big of a deal. It is true that all chillers perform the same primary function, but the similarities end there. In order to achieve maximum effectiveness and satisfaction from your industrial chiller, there are some things you should look for.

Is a Chiller the Best Solution for Your Needs?

Cooling needs vary depending on many factors; like the type of equipment you use and the functions you need. Chillers work well for temperature regulation in machines that use water and other fluids. Chillers are frequently used in the healthcare field, food and beverage services, and some in factories. 

An industrial chiller regulates the exact temperature you need, which in turn lessens the risk of an equipment breakdown by ensuring your equipment is functioning safely at all times. You can also purchase sensors to go along with your chiller to monitor the equipment and prevent or deal with any failures that arise before they turn into serious issues.

Choose the Appropriate Size Chiller

First and foremost, you must choose the right size chiller to ensure functionality, optimal performance, and maximum cost efficiency. The optimal size is based on how much heat your application generates, plus additional power required to maintain temperature under varying loads. 

When you work with an experienced chiller technician, they will help you choose the best-sized chiller to meet your needs.

Use Chiller Performance Curves

You can use the chiller performance curves to help you choose a chiller model that will meet or exceed the required capacity based on the chilled water supply’s temperature and the highest expected ambient air temperature. You should consider the application’s safety margin as it relates to available frame sizes to maximize your chiller’s value.

Check Pump Performance Curves 

Next, check the available pump performance curves to make sure the pump will provide enough pressure at the design flow rate that will satisfy the application. Keep in mind that some liquid-cooled systems contain small coolant flow paths or longer distances with higher pressure than average.

Environmental Friendliness 

An environmentally friendly chiller can save not only the environment, but it can also save your business thousands of dollars a year— and it doesn’t hurt your public image either. Cooling keeps your machines safe and efficient, which allows for faster manufacturing. 

With an industrial chiller, you can stop worrying about how efficient your machines are and turn your energy toward making your business the best it can be.

Custom OEM Chillers

If you are having trouble finding exactly what you’re looking for in a chiller, consider purchasing from a company with custom OEM chiller solutions. When it comes to highly complex and long-term development projects, it makes a lot of sense to consider the issue of process and component cooling early on. 

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5 Things You Didn’t Know About Chillers

Chillers have become an essential HVAC component for a wide range of commercial facilities from hotels and hospitals to restaurants, sporting arenas, and even industrial and manufacturing plants. If you’re getting ready to invest in a new industrial chiller, there are a few key facts you should know about them.

1. Chillers Can Save Your Business Money

Modern industrial chillers are more efficient than ever, and many meet energy efficiency minimum requirements. This increased energy efficiency can add up to thousands of dollars in your business’s pocket.

2. Chillers Are Environmentally Friendly 

There are even chillers these days that are eco-friendly. These industrial chillers will give you the most cost savings in the long term because they run super-efficiently. Cooling keeps your machines safe and productive, which leads to a faster manufacturing process.  

3. Chillers Improve Quality Control

Quality control is an integral part of a business that allows you to save money while keeping customers happy. It’s vital to ensure there are safeguards in place in case technology fails, and to protect your organization from a hard financial hit in terms of lost data and revenue should a disaster occur.

Preventative measures are key to minimizing the side effects of a disaster. An industrial chiller is one way to do this, decreasing the risk that your equipment will break down. Industrial chillers ensure your equipment functions safely around-the-clock. 

When equipment breaks down, it can also break the bank. When you ensure you take all measures to stop equipment failures and deal with them when they do happen, you will save yourself a lot of time and money.

4. Industrial Chiller Training

It’s one thing to know how to use your equipment, but knowing how to teach someone else how to use it is a different story. HVAC chiller training should be a key feature for all equipment you buy. You should also expect the company from which you buy your chiller to help you learn about the equipment so you can learn best practices to operate it and handle any problems without having to rely on a service call.

At KKT Chillers, we offer online HVAC chiller training programs to help you become certified in any application-specific chillers we offer. Chiller training programs come with different levels to grant you access to additional troubleshooting, case studies, and priority tech support as you need it.

5. Chiller Use Spans Many Industries

Industrial chillers are used for controlled cooling of products, mechanisms, and factory machinery in a broad range of industries, including food processing and preparation, pharmaceuticals, commercial printing, metal finishing, laser cutting, and transportation manufacturing. 

Chillers are also commonly used in the medical field. Medical chillers are most frequently used to keep medical equipment running smoothly. They are also used to help lower patients’ body temperatures during certain procedures and maintain proper temperatures for medical samples.

There’s a lot to learn about chillers and how they can benefit your business. However, no business or industry is the same, so it’s important to keep in mind your specific needs when it comes to chillers. 

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Technologies Your HVAC Company Should Know

Technology changes every industry, and HVAC is no exception. What should you know about an HVAC company before working with them?

If recent technology has a theme, it’s customization. Recent developments in the HVAC field make it easier to source equipment that does exactly what your business needs and nothing else. It also opens the door for HVAC chiller training, giving you the freedom to maintain equipment and avoid emergency situations without relying on service calls. Read on to learn what your HVAC company should know about. 

Original Equipment Manufacturing

Original Equipment Manufacturing, or OEM, is a way of building equipment that’s customized to your company’s exact needs. For example, you might get a custom-made chiller with highly specific capabilities. 

While one may think that comes with a hefty price tag, this could actually save your company money by eliminating functions you won’t use. With the rise of OEM, you can outsource the construction of specialized equipment without sacrificing detail or relying on mass market models that don’t fit your needs. 

Chillers vs. Cooling Towers

Depending on the type of equipment you use, the functions you need, and the overall size of equipment, your cooling needs can vary. As you can see, there’s no one-size-fits-all option when it comes to HVAC. In some cases, you may want to look into cooling towers.

Chillers work well for temperature regulation in machines that use water or other fluids. They’re commonly used in the medical field, food and beverage operations, and some factory applications. Cooling towers work when lowered into overheated water, cooling both it and the machine through heat exchange. These are used in large-scale HVAC applications such as oil and gas refineries, thermal power plants, and some production plants.

Software Collaboration

Technological advancements aren’t all about the hardware. The latest models, in fact, include software integration to help regulate equipment functions for you. This helps your machines operate in a more precise and cost-effective way.

KKT Chillers offers the Vario Line of eight new chillers with software to regulate and optimize their performance. The addition of this software and a variable refrigeration cycle means these machines can operate at a range of 6 to 28 kW. It also means the machines can operate safely without the addition of special components, which further drives down costs.

HVAC Chiller Training

It’s one thing to know how to use your equipment, but knowing how to teach someone else how to use it is quite another. HVAC chiller training should be an essential feature for any equipment you purchase. Moreover, you should expect your HVAC company to help you learn about the equipment they manufacture and install, so you know how to best operate it and handle problems without relying on service calls.

KKT Chillers offers online HVAC chiller training programs to help you become certified in any application-specific chillers we offer. There are multiple tiers of training programs that give you access to additional case studies, troubleshooting, and priority tech support when you need it.

Final Thoughts

Regardless of your type of business, HVAC is a vital consideration for your equipment. After all, inadequate cooling will mean your machines are less efficient and potentially more dangerous for your workers. And that could mean hiking up your insurance rates. You need to choose the HVAC company that can best address these concerns and help your bottom line.

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Easy Ways to Save Your Industrial Business Thousands

During the COVID-19 pandemic, businesses in countless industries have lost millions of dollars. Chances are you’ve had to come up with innovative ways to combat this global struggle.

In these uncertain times, it is more vital than ever that you save money wherever possible. For industrial companies dealing with manufacturing shutdowns, layoffs, and other issues, it can be difficult to see a light at the end of this tunnel. Below, we’ve compiled a list of straightforward ways to save your industrial business thousands of dollars and pull you through this global pandemic. 

Reducing Costs

While it’s easier said than done, reducing shipping costs is one of the easiest ways to save money in an industrial business. This can be accomplished by changing the packaging. By reducing the weight or changing the material it is made of, businesses can easily save money.

Getting rid of surplus is also an excellent way to reduce the cost of manufacturing. Using smart technology to monitor supply can aid in this, eliminating the excess stock and saving the money it would have cost to produce it.  

While it may seem obvious, production costs can also be cut down with increased automation. In today’s world, it doesn’t seem likely that human involvement will ever be 100% cut out. But you can still seek to replace any repetitive tasks being done by manual workers with an automated system. 

Quality Control

Making sure that everything is up to standard is easily the best way to save money in an industrial business. After an assessment, it is important to maximize the changes you make and implement them immediately. Making sure that there are safeguards in place for when technology fails is extremely important so that you will not lose thousands in case of an emergency. 

Before an emergency even happens, it is even more important that you take preventative measures against failure. An industrial chiller is one way to do this, lessening the risk of an equipment breakdown. Industrial chillers ensure your equipment is functioning safely at all times. Companies can also purchase sensors to monitor their equipment and make sure that any failures are either entirely prevented or can be dealt with before they become a serious problem. 

Equipment breakdowns are extremely costly. Ensuring that you have taken all possible measures to stop them and to deal with them quickly when they do happen will save you on these costs. They are, of course, not entirely preventable. But you can still save thousands by investing in technologies like industrial chillers and stopping the ones that can be stopped.  

Upgrading To More Efficient And “Greener” Technology

Not only is greener technology better for the environment and your public image, but it can also save you thousands of dollars every year. Every day you probably use countless technologies to maintain your facility. The equipment has to be powered and maintained; the location has to be well-lit, and several other costs must be taken care of. If these technologies could be greener and more efficient, you could cut down on daily costs. 

Consider investing in energy-efficient lighting and manufacturing equipment. You can use smart technology that turns off equipment that is not in use. In order to make sure your equipment is running as efficiently as possible; it needs to be well-maintained. 

Investing in an environmentally friendly industrial chiller has the potential to save your business thousands of dollars. Cooling keeps your machines safe and fast, speeding up manufacturing. With an industrial chiller, you can stop worrying about how efficient your machines are and turn your energy toward making your business the best it can be.

We will get through this pandemic together. But even after we do, you can save thousands of dollars each year by following these steps. 

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What Is OEM Chiller Manufacturing?

What is OEM? 

OEM, stands for Original Equipment Manufacturing, and is a type of manufacturing. OEM allows the client to customize a product to their exact needs, creating an opportunity for the client to utilize the chiller for a highly specific purpose. 

OEM can bring many positives to the table when it comes to purchasing a chiller that is both effective and financially viable for your business. 

Did you know that OEMs can eliminate unnecessary costs by getting to the crux of what your industrial business needs in a precise way? This eliminates the need to purchase a chiller that is unnecessarily large or complex, and instead gets exactly to the issue right away.

OEM chillers are a way for a company to outsource manufacturing without compromising on detail. Instead of funding a full in-house manufacturing of a specific product or part, the company can reach out to an OEM manufacturer to create their product. 

An OEM chiller manufacturer can take on your company’s needs and design a chiller that works exactly as your industrial business needs it to. They can also bring their own ideas to the table, helping your company to achieve the desired results while cutting down on excess costs.

OEM chiller manufacturing used prolifically across many different industries, including:

  • Medical Practices: OEM chillers are often used to cool high tech medical equipment like X-Ray machines and CT scanners. This is essential both for the rigorous maintenance of this equipment, and the safety of patients and doctors. 
  • IT Companies: IT companies can benefit from chillers to keep servers and other high-energy hardware cool. 
  • Construction Companies: Construction companies can benefit from chillers by using them for tools and equipment that needs to stay cool. 

2. What are Chillers? 

Chillers are used across all the industries listed above in order to prevent equipment from overheating. Chillers circulate cooling liquid safely within the equipment, allowing the device to maintain a safe temperature and work efficiently. 

Chillers use different methods of cooling depending on what is needed, such as the type of equipment being used. For example, a cooler in a car engine operates by circulating a cooling agent throughout the engine block to prevent overheating. Conversely, a chiller used in some medical devices uses remote tanks to circulate chilling liquid. 

3. Why Does My Industrial Business Need Chillers? 

Chillers are vital for most industrial businesses for a multitude of reasons. Across the world, OEM chillers are used to assist businesses thriving in their industry. These reasons include:

Insurance Purposes

If your device is not cooled to the required standard, an instance of overheating could lead to drastically expensive repairs that are not covered by your insurance policy. Most industrial insurance policies are only claimable if the equipment is cooled to the manufacturer’s standards. The overheads on industrial equipment can be enormous, and without proper chilling, the bills will fall directly at your door.

Safety Risks 

Of course, one of the biggest risks of operating equipment without chillers is safety. An overheating device, particularly devices used in direct contact with human beings, such as medical equipment, can cause catastrophic consequences. 

Did you know that the safety risks of an overheating piece of equipment include burns and severe electric shocks? Using chillers effectively can alleviate the risks of equipment overheating, protecting workers, clients, medical patients and building residents from injury or potentially even death. 

Productivity

Chillers are also essential in maintaining productivity levels in your industrial business. Long cooling times of industrial equipment without chillers slow down productivity, making the whole company move at a slower pace. The use of chillers can make operations more efficient by reducing the cooling time of equipment. 

Some companies decide to cut corners by allowing equipment to overheat, taking serious risks to the health of their staff. Don’t take the risk; purchase an appropriate chiller for your industrial equipment.

Final Thoughts

Overall, OEM chiller manufacturing can benefit your industrial business in many ways. Between the cost-effectiveness of choosing an OEM manufacturer, the precision with which your chiller will be designed and manufactured, and the safety benefits and productivity boosts, why not contact an OEM chiller manufacturer today?

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Chillers vs. Cooling Towers: Which Device Do You Need?

If your industry uses large equipment that is prone to overheating, it is likely that you need chillers and cooling towers in order to keep your equipment safe and efficient. Although chillers and cooling towers are a big investment for any company, there are many benefits to purchasing and installing a chiller for your business.  

Nevertheless, deciding to invest in a chiller or cooling tower is a decision that requires much research and consideration. Depending on the size of your equipment, the type of device and the purpose of use, your cooling needs will be highly specific. In order to fulfill exactly what is needed, it is necessary to choose which type of cooling tower or industrial chiller your business needs for its machinery.

Read on to find out the kind of chiller or cooling tower your business needs!

Chiller Uses

First, let’s start with chillers. The global chillers market is estimated to be worth $9.5 billion, making it a highly lucrative industry. There are plenty of companies that will promise you that their chiller manufacturing services will fulfil your needs. The truth is, though, that you need to find out for yourself. 

Chillers are highly effective in reducing the temperature of machinery that uses water or other fluid. They are commonly used in medical industries, food and beverage, factory machinery and more. 

A chiller can help a business increase their safety by not allowing machinery to overheat before, during, or after use. Chillers are vital for worker safety too, as overheating machinery can cause burns and electrical fires, among other hazards. Any industrial business that wishes to assure worker safety and productivity at all times should invest in a chiller.

Chillers also range in size, meaning they are perfect for any level of industrial business, whether it is a huge factory operation or a smaller device in a local medical practice.

Cooling Towers

Cooling towers are a fantastic alternative to chillers. Cooling towers are heat exchangers that operate by being plunged into water that is overheating due to industrial machinery. The towers allow water to come into contact with cool air, forcing some of the hot water to evaporate and cooling down the overall temperature. This continues in a cycle by lowering and rising the cooling towers in a formulaic motion.

Some industries and equipment that can benefit from cooling towers are:

  • HVAC: Particularly for large scale industrial HVAC operations, such as in factories, cooling towers are highly useful.
  • Medical practices
  • Oil and gas refineries 
  • Thermal power stations 
  • Plants that produce textiles, rubber, tobacco and other products

Cooling towers are usually used for large scale operations such as these, and are therefore less suitable for small scale operations such as individual medical machinery. Unlike chillers, cooling towers are less varied in size, making them less accessible for small companies.

Benefits of Chillers and Cooling Towers

No matter which cooling equipment you choose to purchase for your industrial business, both have similar benefits that are listed in full below. Make sure to consider all the benefits that chillers and cooling towers can offer!

Safety 

As previously mentioned, without using chillers or cooling towers, your industrial business runs a high risk of equipment overheating. This can have devastating consequences, including posing a grave safety concern to workers or clients/patients nearby. Installing the right kind of cooling equipment for your machinery is crucial for keeping others safe.

Insurance

For insurance purposes, it is essential to install cooling equipment in your industrial business environment. Most corporate insurance firms will not cover accidents or damages caused by overheated equipment if the cooling advice has not been followed by the business. This means that you are required to follow manufacturer instructions closely for all your equipment that is an overheating risk. 

Productivity

Without adequate cooling or chilling facilities, your industrial business will lose productivity and be inefficient. This is because large equipment such as X-Ray machines or HVAC equipment will require a cooling-off period once used, if it is not installed with cooling equipment. 

This will mean they cannot be used for a portion of the day, slowing down the entire process of your operation.

Final Thoughts

Whichever type of cooling equipment is better suited to your business, you can find more information about how they work and the cost of each online. Purchasing this equipment should not be done until thorough research is conducted and industry professionals are consulted. 

Make sure to reach out to a knowledgeable manufacturer before choosing your cooling equipment!

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How Do Industrial Chillers Work?

If your business uses industrial machinery of any kind, it’s likely that industrial chillers will prove to be a very wise investment for your daily operations. Industrial chillers are used in a wide range of business environments, ranging from food and beverage production to injection moldings and semiconductors. 

The widespread usage, combined with a growing understanding of their benefits has seen the industry grow at a rapid rate while it is expected to surpass $13.25bn by 2026. Now is the time for your business to open its arms to their benefits.

Before making the investment, though, you should familiarize yourself with how industrial chillers work. Here’s all you need to know:

The Industrial Chiller’s Function

Broken machinery costs US businesses millions of dollars every single day. In fact, research shows that machinery faults (not including boiler problems) account for one-third of all losses surpassing $3m. In many cases, the damages are caused by overheating. An industrial chiller solves this issue by transferring heat from the source location to another.

The process will keep the equipment at a consistent temperature while also maintaining the right pressure levels. In turn, this can deliver a wide range of benefits for your business including:

  • More efficient machine operations
  • Reduced threat of machine failure
  • Reduced maintenance requirements
  • Increased energy efficiency
  • Greater levels of automation

Ultimately, an industrial chiller has the ability to save time and money for the business and its staff. The final result is a more efficient operation that guarantees the highest-quality products.

The Three Working Principles Of Industrial Chillers

Industrial chillers use three working principles to ensure that machinery is kept at suitable temperatures throughout all operations. They are:

  1. The Phase Change: In which liquid coolants turn into gas when heated and condensed back to a liquid when cooled.
  2. The Heat Flow: In which energy naturally transfers itself from high concentrated environments to low concentrated environments.
  3. The Boiling Point: This either increases or decreases in reflection of the liquid’s pressure at any given time.

Key Parts Of Industrial Chillers

The industrial chiller uses a process known as the refrigerant cycle (explained below) to successfully remove and treat the heat gases. To do this, it uses the following parts:

  • The Evaporator: turns a refrigerant liquid into a gas through evaporation.
  • The Compressor: turns low-pressure liquid into high-pressure gas.
  • The Condenser: actively removes heat from the high-pressure gas.
  • The Valve: treats the gas and prepares it as a liquid for the evaporator.

The Three Types Of Condensers

Industrial chillers rely heavily on the function of the condenser. While lesser-used alternatives do exist, the three main types of condensers are:

  • Water-cooled industrial chillers that use an external cooling tower to cool hot gases and refrigerants back into a liquid.
  • Air-cooled industrial chillers that use ambient air to reject hot gases and refrigerants while cooling heat back into a liquid state.
  • Absorption industrial chillers that absorb the gas coolant and recycle the diluted solution through a heat exchange.

How Industrial Chillers Operate

An industrial chiller transfers heat away from the source of overheating by utilizing a water (or water/glycerol) solution. Thanks to the three naturally occurring principles, the heat can be transferred back and forth to the chiller.

Most industrial chillers also use a pump system and liquid reservoir to circulate the liquids and gases to/from the chiller. In essence, then, the heat is transferred away from the machinery and becomes cool due to the cooling temperature of the water or water/glycerol solution. 

Of course, in an air-cooled industrial chiller, the liquid is replaced by the ambient air, although the basic operations are largely the same. Chillers also rely heavily on the cooling refrigerant, which is responsible for facilitating the state phase changes between gases and liquids. 

This is known as the refrigerant cycle, because the compression turns the liquid to a gas and then back to a liquid. The refrigerants are chemical compounds, which will vary depending on the temperature requirements for the intended application.

The cycle is completed by the following steps:

  1. The evaporator is used to boil the heat from the process water, transforming it from a liquid to a gas. 
  2. The gas then enters the compressor, where it becomes a high-pressure gas. 
  3. The high-pressure gas enters the condenser where the water or air ambient is used to cool it to a liquid.
  4. The high-pressure liquid enters a valve that subsequently determines how much refrigerant will be transferred back to the evaporator.
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Best Solutions for Keeping Medical Devices Cool

When your medical business works with medical devices, it is imperative that you regulate their temperatures in an effective way. Otherwise, their efficiency and functions can be significantly compromised, which may also cause safety issues for patients and workers alike.

The World Health Organization states that policies, strategies, and action plans should be in place for all medical devices by national health plans. However, businesses should take accountability too. Many medical devices and processes need to be kept chilled, refrigerated, or frozen in order to be effective, including but not limited to:

  • Lasers
  • Diodes
  • Thermal pipes
  • Electronics
  • Scanners

So, what are the best cooling facilities on the market for medical devices? Let’s find out…

1. Medical Chillers

Medical chillers are a collection of specialized temperature regulation facilities that can be used to protect a range of equipment including MRI scanners, PET scanners, oncology equipment, and CT scanners.

Their main function is to keep all parts of the equipment cool throughout medical procedures. In most cases, they use water-cooled or air-cooled tech to transfer heat away from the source of overheating. This can be achieved in a number of ways, including continuous flows or intermittent cooling. 

The medical chiller industry is predicted to surpass $12.7bn by the end of 2027. Their potential benefits for medical care businesses include:

  • Remove the threat of overheating and breaking down mid-treatment
  • Reducing the post-treatment cooling times
  • Maintaining a more comfortable room temperature for patients and medical teams
  • Saving money due to reduced repair works and quicker processes
  • Improved machine efficiency and accuracy

If using big medical devices that reach high temperatures, medical chillers are essential for the sake of performance, productivity, and profitability. Thanks to advancements in technology, medical chillers are now more compact than ever before, meaning they can aid performance levels without impacting the look or atmosphere of a medical environment.

2. Cooling Vests

The need for cooling shouldn’t be limited to equipment and medical devices. It is equally crucial to consider the health of the doctors and surgeons that will use those facilities. Being around x-ray machines, lasers, and equipment that reaches high temperatures will expose employees to the high temperatures for long periods. Cooling vests are, therefore, an essential addition.

Studies show that productivity can fall by 4% for each degree over 27C. Given the extended time that surgeons can be under that intense heat, this will result in slower performances and may also increase the threat of mistakes. Cooling vests and related accessories help maintain a better core body temperature while they can be worn for long periods without any discomfort or side effects. Cooling vests and accessories are also available in multiple sizes for optimal convenience.

3. Spot Coolers

As confirmed by the FDA, a wide selection of medical tools, devices, and items need refrigeration and to be stored at the appropriate temperatures. The list includes lab reagents, dialysis, sterilants, skin substitutes, and dental products. Similarly, organ preservation will require a cooler temperature. 

However, you won’t always require cooling for the entire room. Spot coolers are the answer. The portable units are essentially a medical version of the A/C facilities you’d find at home. This allows you to drop the temperature in a specific area. 

Aside from being a cost-effective solution that doesn’t have to impact other facilities within the room, it gives you the chance to keep medical devices and products cool as they prepare for transit to another part of the building or medical center. The fact that you won’t need them at all times means a small number can serve the whole building.

4. Medical Fans

While research papers dispute the claims that fans can increase the risk of infection, those proposed risks should not be ignored. The fact is that household fans will see germs circulate, which could pose a threat in medical surroundings where patients could be ill. It’s always better to be safe than sorry, which is why medical fans are the safest solution by far. 

Aside from protecting people, they will protect medical devices too. Medical fans are specialized to provide the cooling attributes without the risks associated with more traditional systems. 

They use sealed enclosures and technologies that use heat transfers to keep internal areas hot and external features cold. In turn, this keeps the unit cool from a user’s perspective, which will then drop the localized temperature and boost air circulation. It adds comfort for people and keeps delicate medical tools at the right temperature too.

Conclusion

Medical facilities run the risk of getting very hot due to the machinery used and potentially compact spaces. Whether protecting devices or people, the right choice of cooling systems will make a world of difference.