Most manufacturing processes generate heat, referred to as process heat. In many cases, that heat can jeopardize the quality of the product, cause higher rates of rejection or spoilage, and, in applications such as pharmaceuticals, even endanger lives. Controlling this process heat is vital to successful manufacturing. Many manufacturers use water chillers to regulate the temperature of the environment.  

We’ve already mentioned pharmaceuticals, but other manufacturing processes require industrial chillers, including:

• Plastic extrusion: As it cools from a molten state, plastic often requires a specific temperature to achieve the desired qualities.
• Machine shop operations: Excessive temperatures can affect precision and compromise tool life.
• Food processing: Incorrect temperatures can lead to food spoilage and other problems like insufficient measurements when filling containers.

Industrial water chillers allow manufacturers to control heat and maintain temperature standards within 1 degree for the manufacturing process.

An industrial chiller removes heat from a defined space, typically by routing water through a pathway adjacent to an area or machinery that needs to be cooled. A water jacket in an engine block is an excellent example of this. The water absorbs the process heat. The industrial chiller system routes the warmer water to an outside area for cooling before being reintroduced back into the manufacturing area to repeat the process. 

Water has excellent thermal transfer capabilities, offering a greater degree of operator control and efficiency. Water-cooled chillers, typically located inside and away from the elements, have a life expectancy as long as 20 to 30 years.

Water-cooled chillers work by cooling water through the evaporation process. After passing through the manufacturing area, warmer water is routed back to the chiller, passing through an exchange plate.  Once cool enough, the water is routed back into the manufacturing area, where the process repeats itself. 

Some chiller applications call for a mixture of glycol and water. Glycol helps maintain temperature in the chiller. There are also some glycol blends that inhibit corrosion and bacterial growth in the pipes of the chilling system.

There are several considerations to make when choosing a suitable water chiller for your application.

Water-cooled chillers remain efficient in larger sizes. When making the purchasing decision, it’s always wise to budget for future expansion of your manufacturing operation. Still, you don’t want to have more chilling capacity than you will ever use. Take a close look at what you need now and what you will need in the future.

Consider the temperatures you need to achieve for the type of manufacturing your company is engaged in. If you’re primarily involved in the same kind of work with the same materials, your water chiller selection must fit comfortably into that range. If you are a contract manufacturer and encounter different demands, your industrial chiller must be flexible enough to handle the temperature requirement for any particular job. Look for water chillers that are programmable  within a narrow range of temperature.

Water is corrosive. Look for water chillers with designs that guard against this, including non-ferrous reservoir tanks and piping.

Another reason companies don’t want to purchase more chiller capacity than they need (now and in the foreseeable future) is that a chiller has a footprint and requires someplace to put it. Remember, water-cooled chillers are best located inside your building. When evaluating a system, make sure that you budget for all the space you need. The space should be a single-use application, so you should avoid storing inventory or other items in the same enclosure.

As you evaluate different types and brands of chillers, consider energy usage. All things being equal, newer systems are almost always more energy-efficient, but some brands are more efficient than others. The best practice is to focus on research to ensure your new chiller is best suited for your needs, in every aspect. 

As with any machinery, the better you maintain your chiller, the more efficiently it will perform and the longer it will last. Before making a buying decision, look at maintenance requirements and whether you can have one of your employees trained to do the periodic maintenance. Set up a maintenance schedule that includes weekly, monthly, quarterly, and annual tasks. 

It is crucial to ask about the availability of parts.  Avoid long periods of downtime waiting on part retrieval by ensuring they have a dealer network that can respond to warranty issues, part orders, and other needs.

Verifying the temperatures you need to achieve in your manufacturing environment is essential to selecting the right type of chiller.

If you are a contract manufacturer, your client should have temperature requirements. Also, consider the application. For a vinyl extruding operation, some vinyls may require different temperatures. A standard clear vinyl may have a different temperature requirement than a fire-resistant vinyl or one with specific light-blocking properties. Always verify this information.

The logistics of your manufacturing floor and the location of your water chiller play a role in maintaining the correct temperatures. Placing new machinery, boxes of inventory, and finished products on your manufacturing floor can interrupt the airflow and raise the ambient temperature, which could affect your industrial water chiller. Avoiding clutter in the manufacturing area is always a good policy, but it is essential for temperature control.

Finally, look for a manufacturer of industrial water chillers that you can rely on for a good product and reliable service. Look for a stable company with a history of performing. Things you should consider include:

• Established: How long have they been in business? 
• Responsiveness of the sales staff: Do they answer your questions promptly?
• Service and maintenance: When your water chiller goes down, manufacturing stops. Can they solve problems quickly? Can they train your staff?
• Follow-up: Does the company have a good network of service people and parts availability?
• Reputation: Check around. Don’t hesitate to ask for references.

GMN USA specializes in spindles and spindle repair for machine shop and CNC applications where process heat is always a factor. For this reason, GMN USA partners with Pfannenberg USA, a manufacturer of industrial chillers. The line of Pfannenberg chillers, available through GMN USA, includes units as compact as 158 pounds that can be mounted on top of a machining enclosure and larger chillers of more than a half-ton that can put out more than 150,000 BTUs per hour.

Visit our website to learn more about the water chillers available through GMN USA!