An industrial chiller is a large-scale refrigeration system used to cool fluids (usually water or a water-glycol mix) to maintain optimal temperatures in various industrial processes. These processes include manufacturing, food and beverage production, pharmaceuticals, and more.

Industrial chillers work by removing heat from the fluid circulating through the system. The chiller unit typically uses a compressor, condenser, expansion valve, and evaporator to transfer heat from the fluid and discharge it as hot air. The chilled fluid is then returned to the process to absorb more heat.

• Air-cooled chillers: Use Ambient air to cool the refrigerant.
• Water-cooled chillers: Use water from a cooling tower or tank to reject heat from the refrigerant.
• Centrifugal chillers: Use centrifugal compressors, ideal for larger systems with very high cooling capacities.

• Air-cooled chillers: These systems expel heat by blowing air over a condenser. They are simpler to install and are typically more suited for smaller or medium-sized applications.
• Water-cooled chillers: These systems use water (often from a cooling tower) to dissipate heat from the condenser. They are more energy-efficient for larger systems but require more complex infrastructure and maintenance.

When choosing a chiller, consider factors such as:

• The cooling capacity (measured in tons or kilowatts)
• The type of process or application
• The ambient temperature and environmental conditions
• The space available for installation
• Energy efficiency and operating costs
• Budget and maintenance requirements

Routine maintenance includes:

• Regularly checking and replacing refrigerant
• Cleaning air filters and condenser coils
• Inspecting the evaporator and compressor
• Monitoring fluid levels and temperatures
• Ensuring proper water treatment in water-cooled systems
• Checking system pressures and adjusting as necessary

Common causes of chiller failure include:

• Low refrigerant levels due to leaks
• Faulty compressors or expansion valves
• Clogged or dirty filters and coils
• Electrical issues or faulty components
• Frozen evaporators or condensers
• Lack of proper maintenance

Cooling capacity refers to the amount of heat the chiller can remove from a fluid in a given period, typically measured in tons of refrigeration (TR) or kilowatts (kW). Refrigeration capacity is related but specifically refers to the ability of the system to lower the temperature of the refrigerant.

• Regular maintenance: Keeping the system clean and in good condition.
• Upgrading to a high-efficiency chiller: Modern chillers are often more energy-efficient.
• Optimizing load management: Avoid overloading the chiller and use the system according to its optimal capacity.
• Use of variable speed drives (VSD): These allow the chiller to adjust compressor speeds to match the required load, saving energy during partial load operations.
• Improving insulation: Ensuring that pipes and ducts are well-insulated can reduce energy losses.

The lifespan of an industrial chiller varies based on usage, maintenance, and the type of chiller. On average, a well-maintained industrial chiller can last between 15 to 25 years. Regular maintenance and timely repairs can extend its life.

Signs that your chiller needs attention include:

• Temperature inconsistencies or failure to maintain setpoint
• Unusual noises from the compressor or fan
• High energy consumption or frequent breakdowns
• Leaking refrigerant or water
• Frost build-up on evaporators or condensers

Yes, many industrial chillers can be customized based on cooling capacity, size, refrigerant type, and other specifications to meet the unique requirements of a given application or process. Dimplex has been manufacturing and providing custom solutions for over 70 years.