What Is an Industrial Water Chiller and Where Is It Used?

That heat needs to be controlled to keep equipment operating within the required temperature range.

This can be achieved using an industrial water chiller to provide controlled cool water to remove heat. Cooling systems are used across many industries from plastics and manufacturing to food production and breweries.

If industrial water chillers are new to you, or you want to know more about the different types and main considerations when selecting, this blog explains exactly what they are, how they operate, and more.

What is an industrial water chiller?

An industrial water chiller is a cooling system designed to remove heat from water circulating through industrial equipment or production processes. Chilled water travels through a pipework circuit to the equipment requiring cooling. As it passes through the process, it absorbs heat before returning to the chiller. The chiller removes that heat, allowing the water to be circulated again at the required temperature.

This creates a controlled cooling circuit rather than relying on the surrounding air or an uncontrolled water supply to remove heat. Industrial water chillers can serve a single machine or provide cooling for several pieces of equipment through a larger distribution system.

Many packaged chillers incorporate equipment such as circulation pumps and buffer tanks, reducing the number of separate components needed for an installation. Our industrial chiller range includes many examples of this arrangement.

How does an industrial water chiller work?

Industrial water chillers operate in a continuous cycle. To start, cool water is circulated from the chiller to the machinery of processes requiring temperature control. As the water circulates, it absorbs heat; this warm water returns to the chiller. Inside the chiller, heat is transferred from the water to the refrigerant through a heat exchanger called the evaporator. The water and refrigerant normally remain in separate circuits. Heat is absorbed by the refrigerant and passes through the compressor, raising its pressure and temperature. At the condenser, the refrigerant releases the heat it has collected. Depending on the exact chiller design, this heat is let out into the surrounding air or into a separate cooling-water circuit.

The refrigerant then passes through an expansion device, reducing its pressure before returning to the evaporator to absorb more heat. Meanwhile, the cooled process water is sent back around the system, allowing the cycle to continue as required.

Where are industrial water chillers used?

Plastics manufacturing

Plastic injection moulding requires material to be heated before it can be injected into a mould; this must then be cooled sufficiently before the finished product can be removed. Chilled water circulating through cooling channels in the mould is an effective way to remove heat and maintain consistent mould temperatures and therefore consistent results. Reliable cooling supports consistent production conditions and reduces the time required for each moulding cycle. At Nexus Cooling we see injection moulding and cooling as one of the most common uses for our industrial process chillers.

Food and beverage production

Production for food and beverages requires temperature control during manufacturing, processing or packaging. Industrial water chillers can be used here to remove heat from processing equipment or support production stages where temperature control is essential. We've worked with countless breweries to provide industrial cooling solutions, as cooling is vital during stages such as wort cooling or fermentation temperature control. Depending on the required temperatures, some breweries use water-glycol cooling circuits instead of water alone for greater security.

Manufacturing and engineering

Industrial machinery generates heat through mechanical operation, electrical components and friction. To maintain performance, this machinery requires components such as spindles or hydraulic systems to remain cool. Even laser equipment may need controlled cooling to remove heat generated during operation. The goal of industrial water chillers in these applications is typically protecting equipment performance and maintaining stable operating conditions; this reduces risk of overheating, improving safety and prolonging the lifespan of machinery.

Medical, laboratory and specialist equipment

Laboratory and medical equipment often generates heat that must be removed to maintain suitable operating conditions. Circulating chilled-water systems in this application provide controlled cooling where relying on room temperature is insufficient. Requirements in this sector vastly vary depending on the equipment, even more so when stable temperatures or continuous operation are necessary.

Air-cooled vs water-cooled industrial chillers

It may sound contradictory, but an industrial water chiller can either be air-cooled or water-cooled. The difference is how the refrigeration system releases the heat removed from the process water. Air-cooled chillers use a condenser and fans to release heat into their surroundings; they're a common part of industrial process cooling and can in some cases be installed without a separate condenser-water circuit. Water-cooled chillers transfer heat into a separate water circuit; this then requires another way of releasing the heat, often through a cooling tower or dry cooler.

Air-cooled systems can be the practical solution where space, installation complexity or access to cooling water makes a water-cooled chiller unsuitable. Water-cooled systems are favoured by larger installations or very particular operating conditions but may require additional infrastructure and maintenance.

What determines the right industrial water chiller for an application?

The starting point is the amount of heat the process needs to remove. This determines the required cooling capacity, usually expressed in kilowatts (kW). Water temperature requirements are equally important. Chiller cooling capacity varies with operating conditions, so a unit's headline capacity isn't black and white.

Water flow must be sufficient to transfer heat from the process back to the chiller. Pumps and pipework need to be compatible with the required flow rate and pressure. The choice between plain water and a water-glycol mixture depends on operating temperatures, exposure to freezing conditions and the equipment requirements. Glycol can provide freeze protection, but its concentration affects heat transfer and pumping requirements.

Installation conditions also influence the choice, including available space, electrical supply and whether the equipment will operate indoors or outdoors.

Industrial water chillers from Nexus Cooling

At Nexus Cooling we supply industrial water and process chillers for applications ranging from individual machines to larger production installations. Our range includes compact packaged units with integrated pumps and buffer tanks, as well as higher-capacity systems for more demanding cooling requirements. We work with nVent Hoffman to provide cooling system design, equipment supply, pipe work installation and commissioning support.

Looking for an industrial water chiller? Speak to Nexus Cooling about your process cooling requirements.