How to Properly Size an Industrial Chiller


When selecting an industrial chiller unit, it's important to select one that you can depend on. North Slope Chillers has a proven formula to help you find the right chiller for your cooling needs.

Understanding industrial chiller units, their uses, sizing, and types is crucial for maintaining optimal temperature levels. These systems provide precise temperature control, protecting materials from hot and humid conditions, and are used in various industries like manufacturing and process cooling.



Understanding Industrial Chillers

Industrial chillers are essential for many industries to ensure equipment works as needed so that your product maintains its high quality. There are different types to select from, depending on sizing, components, and more.

 

Types & Components

Different types of industrial chillers at The Cary Company range in chiller sizing, capacity, and British Thermal Units per hour. Sizes are available from 1/3 tons to 2 tons. We also carry Fluxwrap™ industrial cooling jackets, which can be used with chillers to ensure consistent cooling around your equipment.


3 Factors to Consider When Sizing

There are some factors to keep in mind before selecting your industrial chiller size such as temperature differential, ambient conditions, and British Thermal Units per Hour. This will help ensure you select the right sized chiller for your cooling needs.

 

Temperature Differential

The temperature differential is the difference between your water’s current temperature and the temperature that you need it to be. For example, if the water is at 85°F and you need the temperature to be 75°F, the calculated temperature differential is 10°F.

  • ΔT°F = Incoming Water Temperature (°F) - Required Chilled Water Temperature
  • Example: 85°F - 75°F = 10°F

 

Ambient Conditions

Ambient temperature is the temperature in a specific space such as a room, area, or around equipment. The ambient temperature highly impacts a chiller’s performance. If a chiller is operating outside of its ambient temperature, it will have reduced efficiency. Ambient temperatures can be tuned to temperatures outside of the noted range by the factory.

 

 

Industrial Freeze Chiller, 1/3 Ton, 4,000 BTU/hr Capacity

Ambient temperature: 35°F - 100°F

 

Industrial Freeze Chiller, 1/2 Ton, 6,000 BTU/hr Capacity

Ambient temperature: 40°F - 100°F

 

Industrial Freeze Chiller, 1 Ton, 12,000 BTU/hr Capacity

Ambient temperature: 40°F - 100°F

 

Industrial Deep Freeze Chiller, 1 Ton, 12,000 BTU/hr Capacity

Ambient temperature: 40°F - 100°F

 

Industrial Freeze Chiller, 2 Ton, 24,000 BTU/hr Capacity

Ambient temperature: 40°F - 100°F

 

Industrial Deep Freeze Chiller, 2 Ton, 24,000 BTU/hr Capacity

Ambient temperature: 40°F - 100°F

Ambient temperature is the temperature in a specific space such as a room, area, or around equipment. The ambient temperature highly impacts a chiller’s performance. If a chiller is operating outside of its ambient temperature, it will have reduced efficiency. Ambient temperatures can be tuned to temperatures outside of the noted range by the factory.

 






British Thermal Units per Hour

British Thermal Units per Hour (BTU per hour) determine the thermal/heat energy made within an hour. BTU per hour helps to measure the power of cooling systems such as an industrial chiller. Calculating this is important because it helps to define the cooling capacity you will need later on. 

BTU per hour is found by multiplying your gallons of water per hour by 8.33 and then multiplying that by the temperature differential.

  • BTU/hr = Gallons per hr x 8.33 x ΔT°F
  • Example: (4 gpm x 60) x 8.33 x 10°F = 19,992 BTU/hr


Steps to Properly Size

When selecting your chiller unit, it’s crucial to know how to select chiller capacity and what size will best fit your cooling needs.

 

Perform Load Calculation & Cooling Capacity

The cooling capacity, or chiller tonnage calculation, is the measurement of a cooling system’s ability to remove heat. This can be found by dividing the BTU per hour by 12,000.

  • Tons = BTU/hr ÷ 12,000
  • Example: 19,992 BTU/hr ÷ 12,000 = 1.666 tons

 

Ideal Chiller Size

The last step in the process of deciding on the size of chiller you need is to multiply your cooling capacity by 20% and round up to the nearest whole number. That number will be the ton of chiller that will best suit your business needs.

  • Ideal Size in Tons = Tons x 1.2
  • Example: 1.666 tons x 1.2 = 1.9992 tons; a 2 ton chiller is needed

Installation & Maintenance

To ensure system efficiency, you’ll need to make sure your unit is installed properly and that you keep up with routine maintenance.

 

Proper Installation Practices

1. Position the chiller for use by placing the unit on a flat and level surface, located in a well-ventilated area





2. Connect the inlet and outlet fluid hoses. Confirm they are connected to the proper ports

 

3. Fill the industrial chiller unit's reservoir

 





4. Connect to power and confirm you have the correct supply equipment before plugging the unit in

5. Turn the industrial chiller unit on and make sure to adjust the temperature controller as needed

1. Position the chiller for use by placing the unit on a flat and level surface that is located in a well-ventilated area

2. Connect the inlet and outlet fluid hoses and confirm they are connected to the proper inlet and outlet ports

3. Fill the reservoir

4. Connect to power and confirm that you have the correct power supply equipment before plugging the unit in

5. Turn the chiller on and adjust the temperature controller


Routine Maintenance

For the chiller to work as expected, it’s vital to keep up with routine maintenance.

  1. Keep a detailed daily operations log
  2. Clean filters every three months
  3. Fix any leaks immediately
  4. Clean the system tubes frequently
  5. Regularly analyze the conduct oil and refrigerant

 


We're Here to Help

Every chiller is made to be an efficient and dependable cooling system that you can rely on. We carry a selection of industrial chiller units and industrial cooling jackets. Chillers are available in various sizes: 1/3 ton, 1/2 ton, 1 ton, 2 ton, 5 ton, and 10 ton. Discover which chiller at The Cary Company is the best fit for your company quickly and easily. For more information on how our chillers can help meet your temperature control needs, call our knowledgeable solution providers at 630-629-6600.

How to Properly Size an Industrial Chiller

When you need to cool down a product, don’t go out and buy just any industrial chiller unit. North Slope Chillers has a proven formula for finding the exact chiller for your cooling needs.

Temperature Differential

The first step is to calculate the temperature differential, meaning the difference between the current temperature of your water and the needed temperature of your water. For example, if the water is 85°F, and you need it to be at 75°F, the temperature differential would be 10°F.

  • ΔT°F = Incoming Water Temperature (°F) - Required Chilled Water Temperature
  • Example: 85°F - 75°F = 10°F

British Thermal Units per Hour

Next, calculate BTU per hour. This is important because it will help us define your cooling capacity needed later on. BTU per hour is realized by multiplying your gallons of water per hour by 8.33, then multiplying that by the temperature differential.

  • BTU/hr = Gallons per hr x 8.33 x ΔT°F
  • Example: (4 gpm x 60) x 8.33 x 10°F = 19,992 BTU/hr

Cooling Capacity

Cooling capacity is the measured ability of a cooling system to remove heat. You can find this by dividing the BTU per hour by 12,000.

  • Tons = BTU/hr Ă· 12,000
  • Example: 19,992 BTU/hr Ă· 12,000 = 1.666 tons

Ideal Chiller Size

The final step in finding the ideal size of chiller you need is to multiply your cooling capacity by 20% and round up to the nearest whole number. The resulting number will be the ton of chiller that will best suit your business.

  • Ideal Size in Tons = Tons x 1.2
  • Example: 1.666 tons x 1.2 = 1.9992 tons ; a 2 ton chiller is needed

We’re Here to Help

Each chiller is built to be the most efficient, most reliable cooling system available. Discovering which one will best help your company takes only a minute. North Slope Chillers has these formulas on their website, as well as a program that allows you to input your numbers and does the math for you. You can also call our highly seasoned solution providers at 630-629-6600 for more information of how North Slope Chillers can meet your temperature control needs.

How to Determine Chiller Size Needed