6 Signs Your Facility Needs a Custom Air-Cooled Chiller

While standard air-cooled chillers work well for many industrial processes, some facilities have unique cooling requirements that demand a custom-engineered solution. A custom air-cooled chiller ensures your cooling system is perfectly matched to your process, space constraints, compliance needs, and operational environment.

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Here are six clear signs that your operation would benefit from a custom industrial air-cooled chiller.

1. Unique Process Cooling Requirements

Processes with variable cooling loads, precise temperature tolerances, or multi-stage cooling needs often require custom chillers. Standard chillers may be over- or under-sized, resulting in inefficient operation, temperature swings, or equipment stress.

Example: In plastic extrusion, the cooling load can shift dramatically between production runs, requiring dynamic load management and precise temperature control, achievable only with custom-designed controls and capacity modulation. In , Berg designed a custom air-cooled chiller for Cap-Thin Molds Inc., to meet precise cooling requirements for plastic cap and thin-wall molding.

2. Space and Installation Constraints

Limited space, unusual building layouts, or retrofit projects may call for custom chillers designed with compact footprints, remote condensers, or flexible mounting options. Custom engineering allows chillers to fit into constrained mechanical rooms, be mounted outdoors or rooftops, or incorporate remote condensers to maximize floor space.

Example: In a food processing plant, production space is often at a premium, so the chiller may need to be located outside or in a dedicated mechanical room with non-standard dimensions. In , Berg supplied a space-saving outdoor air-cooled chiller for Delmar Foods, which was designed to fit a limited footprint while delivering reliable process cooling.

3. Harsh or Unusual Operating Environments

Standard industrial chillers are typically rated for mild to moderate conditions. For facilities in coastal, high-humidity, or extreme temperature environments, chillers built with specialized materials and coatings to withstand tough conditions can ensure reliability and longevity.

Example: A chemical processing facility in a coastal region may require marine-grade coatings, corrosion-resistant materials, and climate-specific controls to ensure reliable long-term performance. In , Berg engineered a custom electronics cooling solution for Elta Systems Ltd., designed for deployment on a military vessel operating in harsh marine environments.

4. Regulatory and Industry-Specific Compliance

Industries such as pharmaceuticals, food & beverage, and energy processing must meet strict regulatory standards for temperature control, refrigerants, and operational safety. Custom chillers can be built to support compliance and audit-readiness.

Example: A pharmaceutical plant may need precise GMP-compliant temperature control, validated performance documentation, and redundant systems for critical processes. In , Berg supplied a low-temperature air-cooled chiller to BioVectra Inc., designed to meet stringent pharmaceutical process requirements and validated temperature performance.

5. Integration with Existing Process and Controls

In many industrial facilities, cooling systems are just one part of a larger, interconnected process. Custom chillers can be designed to seamlessly integrate with existing automation systems, SCADA platforms, and remote monitoring solutions.

Example: Berg provided a custom air-cooled chiller for GTUIT's modular gas treatment system, ensuring seamless integration with process controls for remote wellhead operations.

6. Energy Efficiency and Sustainability Goals

For energy-intensive industries, custom chillers can incorporate features like variable frequency drives (VFDs), heat recovery, and free cooling, helping facilities meet energy efficiency and carbon reduction goals.

Example: In a dairy processing facility, waste heat from the chiller could be repurposed to preheat water for CIP (clean-in-place) systems. In , Berg an energy-efficient outdoor air-cooled chiller for a leading dairy products corporation, helping them reduce energy use while maintaining reliable cooling.

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Future-Proof Your Facility with a Custom Air-Cooled Chiller

The right custom chiller does more than solve immediate cooling challenges. It also future-proofs your operation, enhancing:

• Process uptime and reliability
• Operational efficiency
• Long-term energy savings
• Regulatory compliance

To see how Berg's custom engineering expertise supports industries from plastics and food production to natural gas processing and pharmaceuticals, explore our Project Spotlights.

Partnering with Berg for Custom Industrial Cooling Solutions

At Berg Chilling Systems, we specialize in designing and manufacturing custom-engineered air-cooled chillers for a wide range of industries, including food & beverage, plastics, pharmaceuticals, energy, and beyond. We work closely with each client to:

• Understand your specific process and cooling challenges
• Design a solution that maximizes performance, reliability, and energy efficiency
• Ensure smooth integration with your existing systems and infrastructure

What Are the Cooling Requirements for Your Facility?

Understanding your facility's cooling requirements is the first step to choosing the right chiller. Factors such as the size of your space, the heat load, and the nature of your operations all impact the specifications you need. A manufacturing facility might require high-capacity cooling to manage equipment heat, while a smaller office might need a compact solution. 

Evolution Cooling's team excels at assessing these needs, ensuring you select a chiller with the right capacity and configuration. Our tailored recommendations account for operational demands, ensuring maximum efficiency and minimal downtime. Whether you're upgrading an outdated system or installing a new one, aligning your choice with your cooling demands ensures optimal performance and long-term reliability.

What Are the Different Types of Chillers Available?

Chillers are classified into various types, each tailored to specific applications and operational needs. Air-cooled chillers are a popular choice for smaller facilities or locations where water resources are limited, as they rely on ambient air to dissipate heat. These systems are easier to install and maintain, making them suitable for buildings with space constraints or lower cooling demands. However, they can be less efficient in hot climates, where ambient temperatures challenge heat exchange. Water-cooled chillers, on the other hand, are designed for larger installations requiring high-efficiency cooling. These systems use a water source, such as a cooling tower, to manage heat more effectively, offering superior performance even in demanding environments. 

Other types include evaporative chillers, which combine air and water cooling for enhanced efficiency, and hybrid systems that adapt to fluctuating demands. Selecting the right chiller depends on factors such as facility size, energy goals, and environmental conditions. A thorough evaluation ensures a solution that balances operational needs with cost efficiency. At Evolution Cooling, we can provide guidance on the best option for your needs, offering an extensive range of models to fit any facility. 

How Does Energy Efficiency Impact Chiller Performance and Costs?

Energy efficiency is a critical consideration when purchasing a chiller. Choosing an energy-efficient model reduces operational costs and aligns with sustainability goals. Look for chillers with a high SEER (Seasonal Energy Efficiency Ratio) rating or advanced features, such as variable speed drives, to improve performance. 

Please note that Evolution Cooling prioritises efficiency, offering a selection of chillers that not only reduce energy consumption but also enhance long-term savings. Our expertise ensures that you select a chiller designed to meet your energy requirements while keeping utility bills manageable. With the right model, you can achieve both peak performance and cost-effectiveness, ensuring your investment pays off over time.

How Important Is Maintenance and Servicing for Chiller Longevity?

Routine maintenance is vital for keeping a chiller functioning efficiently and extending its lifespan. Without regular servicing, chillers are more prone to reduced performance, higher energy consumption, and unexpected breakdowns, which can be costly to repair. Proper maintenance involves inspecting key components such as compressors, condensers, and evaporators, as well as monitoring refrigerant levels and cleaning filters. Addressing minor issues early prevents them from escalating into significant problems that disrupt operations. Regular maintenance also improves energy efficiency, ensuring the system runs optimally and lowers operational costs over time.

We help to minimise these risks by providing thorough maintenance services, including routine inspections and prompt repairs. With quick access to replacement parts and expert servicing, operational downtime is kept to a minimum, enhancing both the reliability and longevity of the equipment.

What Should You Know About Initial Costs Versus Lifetime Costs?

When buying a new chiller, balancing initial costs with lifetime costs is crucial. While cheaper models may seem attractive, they often come with higher operational expenses due to inefficiency or frequent repairs. 

Our energy-efficient chillers and tailored maintenance plans reduce overall costs, making them a sound investment. By focusing on both upfront affordability and ongoing savings, we will ensure that your chosen system provides maximum return on investment over its operational life. This factor alone makes us the ideal choice for businesses prioritising cost-effectiveness and reliability.

Factors When Buying a New Chiller Unit in Summary

Choosing a new chiller involves balancing technical and practical requirements. By thoroughly assessing your facility's needs and the options available, you can ensure optimal performance and cost-effectiveness. With expert guidance and comprehensive solutions, Evolution Cooling makes it easier to find the perfect chiller unit tailored to your goals.

Want more information on Air-Cooled Integrated Chiller? Feel free to contact us.

With competitive price and timely delivery, linggong sincerely hope to be your supplier and partner.

When it comes to maintaining optimal temperatures in industrial and commercial settings, air-cooled chillers are essential components of the cooling system. These units play a crucial role in managing heat through liquid cooling, ensuring that equipment and processes operate efficiently. Cooling systems are vital for numerous industries, from manufacturing to data centers, where precise temperature control is paramount.

Air-cooled chillers are refrigeration systems that remove heat from a liquid via a condenser that uses air as its cooling medium. This process allows the chiller to cool water or other fluids used in various applications. By understanding the principles behind air-cooling technology, businesses can make informed decisions when selecting the most suitable chiller system for their specific needs.

Chillers play a critical role in regulating temperatures in environments where excess heat can cause damage or disrupt operations. Whether maintaining ideal conditions for production machinery or preserving perishable goods, these systems ensure that processes run smoothly and efficiently. Understanding how chillers function is key to appreciating their importance in HVAC and industrial operations.

Cooling systems are integral to maintaining safe and productive work environments across diverse industries. From large-scale facilities to compact spaces, the ability to effectively control temperatures is crucial for operational efficiency and equipment longevity. Without reliable cooling solutions such as air-cooled or water-cooled chillers, HVAC systems would struggle to meet performance standards.

Now, let's move on to exploring what air-cooled chillers are and how they function within different environments.

Air-cooled chillers are refrigeration systems that remove heat from a liquid through a condenser. Their principles involve using air to cool and condense the refrigerant vapor back into a liquid state. This process allows the chiller to transfer heat from the cool liquid to the air around it, effectively lowering its temperature.

Air cooled chillers operate on the principle of heat exchange, where the hot liquid refrigerant flows through coils in the chiller's condenser. As air is blown across these coils, it absorbs the heat from the refrigerant, causing it to condense back into a liquid form. This cooled liquid is then circulated through the system to remove heat from various sources.

Air cooled chillers have a compressor that pumps the refrigerant through the system, increasing its pressure and temperature. This high-pressure, high-temperature refrigerant then flows through the condenser coils, releasing heat to the surrounding air. The now-cooled refrigerant continues its journey through an expansion valve, which reduces its pressure and temperature before it enters the evaporator coils to absorb heat from the water or air being chilled.

Air-cooled chiller systems are a versatile and efficient way to cool buildings and industrial processes. Here are the key components that work together to achieve this cooling effect:

In conclusion, air-cooled chiller systems provide a reliable and efficient solution for various cooling needs. They are easy to install, require less maintenance, and improve energy efficiency.

Air cooled chillers work by absorbing heat from a process water or coolant and then transferring it into the air. The process begins with the refrigerant entering the evaporator, which absorbs the water's heat. The now-cooled water is pumped through the system to cool the equipment or process.

Air-cooled chillers are often preferred over water-cooled chillers in certain applications due to their lower installation and maintenance costs. Because air-cooled chillers do not require a cooling tower or condenser water system, they are easier and less expensive to install. Additionally, air-cooled chillers are typically more compact than their water-cooled counterparts, making them a better fit for facilities with limited space. This makes them a popular choice for smaller-scale operations or facilities where space is premium.

Unlike water-cooled chillers, air-cooled chillers do not require a cooling tower or condenser water system, making them more cost-effective and easier to maintain. Water-cooled systems are typically more efficient in terms of energy usage, but air-cooled systems are often preferred in smaller-scale applications due to their simplicity and lower installation costs.

Additionally, air cooled chillers offer greater flexibility in placement and installation. Since they do not require a cooling tower or condenser water system, they can be easily installed on rooftops or other outdoor spaces, saving valuable indoor real estate. This makes them a practical choice for businesses or facilities with limited space for mechanical equipment.

Air cooled chillers are widely used in various industries such as plastic manufacturing, food processing, pharmaceuticals, and HVAC systems. Their mobility and compact design make them ideal for smaller spaces or applications where a traditional water chiller may not be feasible.

Now that we have explored how air cooled chillers work and their applications in different industries, let's delve into the role of water in cooling systems and RIGID's innovative approaches to water chillers.

Water chillers are known for their high energy efficiency and minimal environmental impact compared to air-cooled chiller systems. Water chillers can achieve better thermal performance by utilizing liquid cooling technology while consuming less power, contributing to lower carbon emissions and reduced energy costs.

In addition to their energy efficiency and environmental benefits, water chillers offer the advantage of quieter operation compared to air-cooled chiller systems. Using liquid cooling technology helps minimize noise levels, creating a more comfortable and peaceful working environment for employees. This can lead to improved productivity and overall satisfaction in the workplace.

RIGID Technology is at the forefront of developing innovative water chillers prioritizing energy efficiency and environmental sustainability. With a strong focus on research and development, RIGID has engineered advanced miniature and mobile water chiller solutions customized to meet specific cooling requirements across various industries.

RIGID Technology is a pioneer in designing and manufacturing micro refrigeration equipment solutions, offering customized options to meet specific cooling needs. These miniature chiller systems are compact, efficient, and ideal for various applications, from small-scale industrial processes to portable medical equipment.

Mobile chiller systems offer a unique advantage: portability. Unlike traditional fixed units, mobile chillers can be easily transported and deployed wherever cooling is needed. This makes them ideal for a variety of situations. Here are some of the key benefits:

RIGID's mobile chiller systems provide a versatile and convenient cooling solution for a wide range of applications. Their portability, ease of use, and cost-effectiveness make them a valuable asset for any business or organization that requires temporary or on-the-go cooling.

RIGID's customized chiller solutions put you in control of your cooling needs. Contact us today to discuss your project and learn how we can help you achieve optimal performance and efficiency.

As technology advances, the future of air cooling is moving towards more energy-efficient and environmentally friendly solutions. With a focus on reducing carbon footprint, there is a growing trend toward the development of air-cooled chillers that utilize natural refrigerants and innovative heat transfer methods to achieve optimal cooling performance.

RIGID Technology has been at the forefront of this evolution, leading the way in developing cutting-edge air-cooled chiller systems that prioritize efficiency and sustainability. Through its state-of-the-art research and development department, RIGID has consistently innovated and improved its products, setting new standards for the industry.

The future of HVAC chillers is undoubtedly intertwined with sustainability. RIGID's commitment to sustainable practices is evident in its focus on designing air-cooled chillers that minimize environmental impact while maximizing performance. By integrating eco-friendly refrigerants and optimizing energy consumption, RIGID is shaping the future of chiller systems with a strong emphasis on sustainability.

Selecting the appropriate cooling system is crucial for any HVAC setup. Air-cooled chillers offer a cost-effective, energy-efficient solution for cooling large industrial spaces or commercial buildings. With RIGID's expertise in micro refrigeration equipment, you can find the perfect customized chiller system tailored to your specific needs.

RIGID Technology is dedicated to pushing the boundaries of innovation in air cooling technology. Through continuous research and development, it strives to improve the efficiency and sustainability of its chiller systems while offering cutting-edge solutions for various industries.

As technology continues to advance, so does the future of chillers in HVAC. RIGID is at the forefront of this evolution, pioneering new trends in air cooling technology and promoting sustainable practices within its chiller systems. By embracing these advancements, businesses can ensure that their HVAC setups remain efficient and environmentally friendly.

In conclusion, when it comes to selecting a cooling solution for your HVAC needs, RIGID Technology stands out as a leader in providing innovative, customized air-cooled chiller systems designed to meet current demands while embracing future trends in chillers for HVAC applications.