Water-cooled chiller plants have three major components that consume electricity: the chiller, the condenser and evaporator pumps, and the cooling tower fan. The chiller consumes the highest amount of total plant room energy. In certain applications, the energy consumption of a chiller is very significant. 

Röchling required a new comprehensive cooling system for their facility. The forward thinking management elected to pursue a system that was not only reliable and cost effective, but would incorporate industry leading technology for efficiency and built-in designs for redundancy. Their facility required both a cooling tower system and a chiller system. Below are the design features of each of these Thermal Care systems, and the benefits of some of the unique features are explained.

Our simplified business model is to melt plastic and cool it back into the form we want – and cooling water makes this happen. We need to optimize chilled water temperature and flow to ensure that our production machines make consistent finished products. In molding application, we cool the plastic through conduction and convection directly. Blown film is different in that cooling-water cools the air and then an air handler cools the plastic.

Free cooling is a type of process cooling system design that takes advantage of ambient temperatures to reduce or even eliminate chiller operation. Chillers consume large amounts of energy; so, reducing a chiller’s operating hours per year can result in significant bottom line savings for your company.  In this article, we will review a typical free cooling system design, some of the considerations for your system, and finally, how these considerations impact your system’s ability to capitalize on the free cooling operation.