In this article, our attention will be directed towards 6 important factors to consider when deciding which chiller is most convenient for your specific needs:
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The operating principle in Air-Cooled Chillers consists of dissipating heat into the ambient air. They contain a refrigerant whose main purpose is to absorb heat from the processed coolant and then it releases it into the atmosphere through condenser coils cooled by fans. In contrast, Water-Cooled Chillers use water instead of air to reject heat, excelling at managing high heat loads, particularly in larger laboratory or industrial setups. These systems require access to a water supply. Alternative liquids may be used as coolants in closed systems, such as when geothermal cooling loops are used.
image courtesy of PolyScience1
Generally, Air-Cooled Chillers are less efficient than their water-cooled analogues, especially in hot climates. This is because their fans require significant amounts of electricity to operate and draw air over the condenser coils. The cooling efficiency of air-cooled chillers is directly related to ambient air temperature. Water-Cooled Chillers, in contrast, use water (usually grey water) as a coolant to remove heat from the refrigerant. This method makes them work more efficiently, as water's superior heat conductivity demands less energy to cool an equivalent amount of heat.
Air-Cooled Chillers typically require less maintenance compared to water-cooled units. Regular and routine tasks include cleaning the condenser coils at least every three months, brushing or vacuuming them to prevent dust from causing blockages, replacing the air filters, and regularly cleaning the fans and air vents to ensure efficient airflow. Accumulated dust can impede proper cooling, leading to inefficiency. Conversely, Water-Cooled Chillers require more frequent maintenance due to the continuous flow of water, potential for deposits and corrosion, and possibility for water leaks in their system. To ease their maintenance, it is highly recommended to install an in-line filter as preventive maintenance. Water, especially if unfiltered, may carry particles that can block the channels within the chiller's heat exchanger. Employing an in-line filter safeguards the heat removal system and prevents the need for maintenance due to impure water stream and plumbing issues. In closed-loop systems, a water cleaner and clarifier can also be used to help prevent microbial growth.
Air-Cooled Chillers can be noisier due to the operation of the fans. Efforts have been made to reduce noise levels in the air-cooled chillers industry; however, they may still be unsuitable for noise-sensitive environments. This is an advantage for Water-Cooled Chillers as they are generally quieter since they don’t use fans for cooling.
Air-Cooled Chillers generally have lower upfront costs due to fewer equipment and infrastructure requirements; however, their lifespan may be shorter compared to water-cooled chillers. This shorter lifespan may be attributed to a larger number of internal components, which inevitably make them more likely to break, and a rigorous cleaning checklist that, if not performed timely, can significantly reduce their lifespan, especially in warmer regions where increased temperatures can strain the chiller.
Water-cooled chillers typically come with higher initial costs due to the extra equipment and infrastructure needed. Nevertheless, they commonly exhibit extended lifespans and may offer better long-term value if the necessary plumbing is already in place. Operating at lower temperatures reduces wear and tear on the machine’s components, increasing its durability. Additionally, their operation at lower temperatures results in decreased energy consumption, translating into long-term financial savings.
Determining the exact lifespan of a machine can often be challenging, but there are methods to estimate its durability. One approach is to review the warranty terms, as machines with longer warranties tend to be more reliable. However, water-cooled and air-cooled chillers generally do not have different warranties if they are provided by the same manufacturer. Warranties will be much more likely to be different when considering systems from different manufacturers. Another option is to consult the manufacturer for insights into the typical lifespan of the machine, although you may not always get a clear answer.
Air and Water Cooled models Available
(Left) Huber Unichiller 015 with Pilot ONE Air Cooled - (Right) DuraChill Chillers 1.5 HP by PolyscienceAir-Cooled Chillers don't require direct water usage, but they consume more electricity, which could result in increased carbon emissions depending on the energy source. Water-Cooled Chillers use less electricity but there may be environmental concerns related to water usage. As water scarcity and utility prices increase, building water consumption is an increasingly important aspect of sustainability and efficiency. For buildings where water-efficient fixtures and cooling system upgrades have already been made, the final step toward ‘net zero’ water consumption is capture, treatment, and re-use of onsite and auxiliary water sources2. Water use can also be dramatically reduced by using closed-loop, geothermal cooling systems, although such systems can be very costly to install.
Taking all of these factors into account we can conclude the decision between them depends on a variety of considerations including space availability, efficiency requirements, cooling capacity requirements, facility capabilities / limitations, initial budget, and long-term operational considerations.
Choosing the appropriate chiller system necessitates a meticulous assessment of all pertinent variables to guarantee optimal performance and cost-effectiveness.
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Typically, however, unless the ambient air is excessively hot or contaminated or the cooling capacity requirements are sufficiently great to make it unfeasible, labs find it more convenient and economical to opt for air-cooled chillers. They are 'plug and play,' requiring simple setup by plugging in, filling with coolant, and operating. In contrast, water-cooled chillers need plumbing for water supply, and if not available, significant facility modifications may be needed.
Less powerful chillers often only come in air-cooled models. This is because they are easier to cool, and therefore facilities generally do not need or want the complexity of setting up water cooling. Sometimes very powerful chillers only come in water-cooled models because air cooling is not efficient enough to cool them. Consequently, for higher efficiency and power requirements, water-cooled chillers would likely be a better fit for your lab.
You can view our entire selection of recirculating chillers, which includes models from many leading manufacturers, at https://waterbaths.net/collections/chillers.
In today's world, the push for energy efficiency and sustainability is stronger than ever. Companies across various sectors are increasingly seeking ways to reduce their environmental impact while maintaining high levels of productivity. At Berg, we believe that energy efficiency and sustainability go hand in hand with industrial success. Our water-cooled chillers are a testament to our commitment to providing solutions that not only meet the cooling demands of today’s industries but also contribute to a more sustainable and environmentally responsible future.
Water-cooled chillers are renowned for their superior energy efficiency compared to air-cooled systems. This efficiency stems from the fundamental differences in how these systems operate. Water has a higher heat capacity than air, allowing water-cooled chillers to transfer heat more effectively and operate with lower energy consumption. This efficiency is particularly advantageous in large-scale industrial applications where cooling demands are substantial, resulting in significant energy savings and reduced operational costs over time.
Sustainability is a critical consideration for modern industries. Beyond energy efficiency, water-cooled chillers contribute to sustainability by minimizing environmental impact.
Investing in water-cooled chillers is not only an environmentally responsible choice but also a financially sound decision. The energy savings achieved through higher efficiency lead to a quicker return on investment (ROI). In many cases, the initial higher cost of water-cooled systems is offset by the long-term savings in energy bills and maintenance costs.
Furthermore, water-cooled chillers generally have a longer lifespan compared to other refrigeration systems. The stable operating conditions provided by water as a cooling medium reduce wear and tear on the system components, resulting in lower maintenance requirements and extended equipment life. This longevity adds to the overall cost-effectiveness and sustainability of the investment.
Our commitment to innovation drives us to continuously improve our water-cooled chiller systems. We incorporate the latest advancements in materials, design, and technology to enhance the performance and sustainability of our chillers. Features such as variable speed drives, high-efficiency compressors, and advanced control systems ensure that our chillers operate at optimal efficiency under all conditions. Additionally, our systems are designed with durability and longevity in mind, reducing the need for frequent replacements and minimizing the environmental impact associated with manufacturing and disposing of industrial equipment.
Berg understands that each industry has unique cooling requirements. Our expertise in water-cooled chiller technology allows us to tailor solutions that meet the specific needs of various sectors, including pharmaceuticals, food and beverage, manufacturing, and more. Whether it’s maintaining precise temperature control in a pharmaceutical production facility or providing robust cooling solutions for large-scale manufacturing processes, our water-cooled chillers deliver reliable performance while prioritizing energy efficiency and sustainability.
By choosing our water-cooled chiller solutions, you are investing in technology that supports your sustainability goals, reduces your energy consumption, and helps you achieve long-term operational excellence. Partner with us to explore how our expertise and innovative solutions can drive your business towards a greener future.
With over 50 years of experience, Berg offers innovative and reliable cooling solutions tailored to your needs. Our team of experts is dedicated to achieving operational excellence in your industrial processes. Whether you need an air cooled chiller, a water cooled chiller, or a combination, we leverage our expertise to deliver optimal performance and cost-effectiveness. Discover how Berg custom designed and supplied a dual circuit indoor water cooled chiller for ice rink operation
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