Selecting a Packaged Standalone Chiller

By: Adam Wells (Solutions Engineer, Pfannenberg USA, Inc.)

 

When considering a liquid chiller system, precision and accuracy are critical for the temperature control of the application. Innovative cooling equipment is essential to regulate temperatures to ensure effective control. Find out how to select the best liquid chiller system for a given application by following the very important steps laid out here.

Calculate system size

Correct selection and sizing of the liquid chiller system for a given application can make a significant difference in reducing startup waste, achieving higher quality applications, increasing product output, and improving profitability. Calculating the size of the liquid chiller system using correct application details is critical to achieving accurate process cooling with a liquid chiller. Further, the size or capacity of a liquid chiller system must be designed to accommodate the varying workloads and ambient conditions that affect the system.

Performing sizing calculations

The three main factors for sizing are:

  • Incoming water temperature (°F) (also known as processed water temperature),
  • Required chilled water temperature (°F) (also known as the setpoint of the chiller), and
  • Flow rate (measured in gallons per minute, or GPM).

Understanding the liquid medium

Cooling processes can be handled with any one of three different mediums: water, water/glycol, or heat transfer oil. Which fluid type selected depends on the temperature the system must achieve, cooling loads, and process requirements like flow capabilities, cycle times, material, etc. In cases where pure water is not a usable medium for the application, glycol and heat transfer oil can be utilized partially to create a water-based emulsion. Cooling capacity correction factors must be made if glycol or heat transfer oil will be utilized.

Determine appropriate controls

Liquid cooling demands accuracy and reliability for temperature stabilization, while operators need easy-to-use and highly visible controls and indicating lights. Pfannenberg chillers offer microprocessor-based controls that provide control performance, visibility to operators, and are configurable to meet specific application needs. A variety of control features including flow/pressure alarms, ambient temperature alarms and remote communication options are available to ensure optimal and desired results.

Prolong the life of your liquid chiller system

Preventive maintenance procedures should regularly be performed to keep the liquid chiller system clean and well-maintained. Performing weekly, monthly, and quarterly checks will extend the life of a chiller system. Refer to the procedures provided in the manufacturer’s instruction manual. By following some basic guidelines before, during and after installation, users can extend chiller lifespan, avoid mechanical/electrical problems, and ensure that a liquid chiller system will provide a high level of efficiency and reliability throughout its lifetime.

Chillers for Industrial Automation and 3D Printing Applications

By Adam Wells, Solutions Engineer, Pfannenberg USA

In the last several years, the use of Industrial Automation and Industrial 3D Printing technology has increased seemingly exponentially. While these technologies confer major benefits in terms of efficiency, quality, cost, and lead times, they also present unique challenges in terms of protecting the sensitive electronic equipment from heat. The buildup of heat can degrade electronic devices used in these processes, thus reducing their life span and increasing total cost of ownership. These technologies require purpose-built industrial fluid cooling solutions; namely, they require chillers with streamlined design, built for a range of environmental conditions, and available on short lead times. Finding such chillers can be difficult.

Industrial fluid cooling equipment for Automation and 3D Printing environments

Rapid technological advancements over the last decade or so have dramatically increased the scope and prevalence of industrial automation and 3D printing technologies in industrial settings. Many packaging and manufacturing operations, in automotive, food and beverage, and more industries, are moving towards widespread adoption of these technologies in an effort to increase efficiency, reduce staffing needs, and improve quality. In the adoption of this technology, the demand for industrial chillers that meet the unique needs of automation and 3D printing machinery has undergone a similarly rapid period of growth. Chillers, as this article will discuss in greater detail, must be designed and sourced carefully in order to provide sufficient cooling in industrial automation and 3D printing applications.

First, I will set out a brief definition of terms to clarify the technologies this article is oriented towards:

  • Industrial automation is the use of control systems, robots, and/or information technologies to mechanize and control what has historically been human labor. Beyond simple mechanization, though, industrial automation, or IA, includes some level of autonomous process control. Examples of IA processes include CNC manufacturing, the use of robotic arms to construct and move products in manufacturing, and more.
  • 3D Printing is a specific automated process in which a physical object is constructed from a three-dimensional digital model, typically by laying down many successive thin layers of a heated and then extruded material. It brings a digital object (its CAD representation) into its physical form through a layered additive manufacturing process. Undertaken at a far larger scale than benchtop 3D printing for prototyping or hobby use, industrial 3D printing technology is a viable option for producing parts in large quantities at once, all from the same digital model.

In many cases, IA and industrial 3D printing requires the addition of chiller equipment to cool and protect electrical and mechanical components or to cool parts after manufacturing. Motors in CNC manufacturing and large robotic arms as well as motors and pumps in industrial 3D printers often require their own liquid water chillers. Similarly, manufacturing processes that utilize industrial 3D printing alongside other methods, like the printing of caps for aseptic milk containers, require chillers so that printed parts can be water-cooled for release from printing molds or before moving on to the next phase of manufacturing. In all of these cases, the chiller systems ought to be utilized with water handling systems that collect, filter, re-cool, and re-cycle water through the system in multiple cooling cycles.

Packaged chillers enable rapid project development and implementation

Industrial automation and industrial 3D printing are lauded for the benefits they confer on manufacturing processes: higher production rates, increased productivity, more efficient use of materials, better product quality, improved safety, reduced labor needs, and shorter factory lead times. As with all manufacturing methods, there are also challenges that accompany these benefits. One of the primary challenges manufacturers face is that since IA and 3D printing technologies are often implemented to increase speed and efficiency and thus reduce costs, all supplementary technology, like chillers, must also meet speed and efficiency demands. Often most challenging is shortening the initial lead time for acquiring these supplementary technologies. Manufacturers generally attempt to implement IA and 3D printing project as quickly as possible, to reap the benefits of increased efficiency, and so the 8-10 week average lead time for chiller equipment can be a major setback.

Pfannenberg, an industry leader in liquid cooling technology, has recognized the challenge that long lead times pose challenges for manufacturers looking to implement IA and 3D printing solutions in their production projects. Out of a concern for customers’ ability to solve challenges in an efficient manner, and to get projects up and running as quickly as possible, Pfannenberg has begun to offer stock delivery of chillers that are specifically designed for industrial settings like the ones needed for IA and 3D printing projects: low complexity, highly efficient, and with a high capacity-to-physical size ratio, these chillers deliver cost-effective cooling with no manufacturing and delivery lead time.

Pfannenberg’s CCE Series is an excellent example of packaged, off-the-shelf chillers available with little to no lead time. Typically featuring one to three tons of cooling, the CCE Series is ideal for the kind of small, industrial cooling most IA and 3D printing applications require. These chillers feature leading-edge fluid cooling technology, including newly redesigned condensers for more streamlined and efficient cooling operation. What’s more, they can be centralized, using a single chiller that serves multiple cooling needs, or decentralized where each application or machine has its own chiller. This enables manufacturers to tailor water and energy usage to specific process demands, and allows for greater flexibility in expanding production capacity over time.

Chiller design for harsh environmental conditions

Manufacturers must consider more than just lead time when selecting fluid cooling equipment for IA and 3D printing equipment, though. Some manufacturing and packaging environments, particularly those with more heavy-duty manufacturing processes, can pose additional challenges for chiller equipment. Though 3D printing tends to take place in slightly cleaner facilities, environmental conditions should always be considered before purchasing industrial fluid cooling equipment.

Industrial fluid cooling equipment should be designed to function well even in hot, dirty environments, and fluid cooling OEMs should work with manufacturers to determine the proper equipment and placement for that equipment in any given environment. Chillers in heavy duty manufacturing environments should be designed to withstand corrosion and buildup of dirt and grime. Pfannenberg’s chillers, for example, are powder-coated rather than painted to improve corrosion resistance, and include micro-channel condensers heat exchanger coils to resist grime buildup in dirty manufacturing environments. The chillers also feature a filter alarm to detect any decrease in performance due to air contamination.

In particularly dirty environments, or manufacturing facilities where the only available space for chillers in is a boiler room or other extremely hot environment, outdoor placement of chiller equipment may be indicated in order to maintain efficient operation. Outdoor placement is also indicated where chiller equipment may pose risks to personnel due to its loud operation or heat emission, or where size is of concern. These chillers, though, need additional environmental protections in order to be able to withstand rain, sleet, snow, sun, and more during outdoor operation.

Pfannenberg has developed the EB Series for higher-demand indoor or outdoor chiller operation; with capacities ranging from five to eight tons of cooling, these chillers are suitable for any outdoor conditions except for sustained extreme cold temperatures. While the majority of manufacturers rely on Pfannenberg’s chillers for a 10-20ºF temperature delta, the company’s engineers can also collaborate with manufacturers who have more significant cooling needs in either indoor or outdoor environments.

Conclusion

Industrial fluid cooling technology is a critical component to implementing industrial automation or industrial 3D printing systems in a wide range of manufacturing and packaging applications. In order for these IA and 3D printing projects to succeed, manufacturers need to be able to source efficient, reliable, and rugged chillers within extremely fast turnaround times. A departure from previous industrial chiller demands, the challenges faced in industrial fluid cooling for IA and 3D printing require purpose-built, leading edge, and packaged chillers that can be sourced quickly and relied upon for streamlined operation in a wide range of harsh environments.

Pfannenberg EB 2.0 ECO Chiller Reduces Energy Usage and Operating Costs

Pfannenberg‘s New EB 2.0 ECO chillers take advantage of the inverter technology to ensure a direct response to cooling demand. This keeps both energy consumption and operating cost to a minimum, while the range of cooling capacity and durability of the units is increased significantly.

Maximum Efficiency with Inverter Technology

The inverter technology helps minimizing energy waste and reduce power consumption up to 65% while lowering operating costs. This responsiveness to cooling demand also increases the range of cooling capacity significantly – by 50-100% – and extends the product’s lifespan. Designed for indoor or outdoor operation, the new chiller design is perfectly suited for heat dissipation in combination with passive indoor cooling systems (PWS/PWW).

The new EB 2.0 ECO Chiller features a hot gas bypass refrigerant circuit, internal hydraulic bypass circuit, and non-ferrous hydraulic circuit. The electrical tank level switch and coolant flow switch simplify operation, along with the programmable smart controller and wired remote control. The new EB 2.0 ECO Chiller uses R410a environmentally friendly refrigerant, and features a micro-channel condenser for greater resistance to dirt and debris buildup in outdoor environments, and thus more efficient operation over time.

Pfannenberg’s new chiller product design is based on customized units that have been proven to deliver high performance, efficient operation, and reduced costs in industrial applications all over Europe. For more information, visit https://www.pfannenbergusa.com/liquid-cooling/eb-series-eco-chillers/.

Liquid Cooling Solutions, the Best Choice for Complete Plant-wide Machine Cooling

When it comes to Thermal Management, cooling each machinery or electrical cabinet separately is usually the solution chosen by most of the industries. However, this leave a valuable optimization potential untapped.

Maximum efficiency cooling for a whole system can be achieved with a cooling system solution consisting of air to water heat exchangers and water-based chillers. These ‘Liquid Solutions’ cool the complete assembly and offer significant benefits compared to traditional approaches such as cooling with ambient air.

How does it work?

A closed loop cooling or semi open system is used to provide cooling to the entire plant assembly. These might be electrical enclosures, processes or individual machine parts such as spindles, motors or hydraulic equipment.

Liquid Cooling Solutions

In a closed-loop system, electrical enclosures or assemblies are cooled with cold water at a specified inlet temperature which is pumped through a pipe system. Flowing through the electrical enclosures or assemblies, the water is warmer when it returns to the chiller. This creates a temperature delta which the chiller equalizes by cooling the water from the outlet temperature down to the inlet temperature.

The process chiller system feeds cold water into the application inside the factory hall or outdoors and the constant flow temperature significantly improves machine availability and machining accuracy. There is no other cooling media being as efficient as water cooling.

The best Liquid Cooling Solution: Combined Chillers and Air to Water Heat Exchangers

The combination of application-specific process chillers with air to water heat exchangers is particularly suitable for applications in which heat must not be dissipated in the immediate environment, where the ambient air is too aggressive to allow the use of traditional enclosure cooling units, where high-level protection is required (up to IP 65) or where the cooling devices must be maintenance-free.

The air to water heat exchanges are all cut-out-compatible and fit in the housing of all available electrical enclosures. This means that machine and plant manufacturers, end users and distributors benefit from higher flexibility, and save costs on warehousing and servicing.

The advantage of an intelligent system solution with application-specific chillers and air to water heat exchangers is that the dissipated heat can be moved directly from the factory shop floor via air channels or an outside chiller system. It also offers very high reliability and problem-free operation as all the components of the system are chosen to work together perfectly. Low maintenance, cut-out-compatibility and energy efficiency optimize energy consumption and keep operating costs to a minimum. The integrated concept and numerous options allow the system to be adapted to almost any application, even with changing conditions.

Application-specific configuration

EB 2.0 Group

Pfannenberg’s experts work with their customers to develop application-specific chiller systems. To achieve exactly the right configuration, it is essential to:

  • First determine the heat load for the whole assembly.
  • The second step is to specify the type of cooling medium (ideally water), the target temperature and the flow quantity which the system must deliver in the actual application. This process should take into account how the heat is transmitted to the cooling medium and the type of refrigerant necessary to operate the refrigerant circuit. The type of cooling medium and which chiller model is used depends on whether usable process water is available at the factory and if so, whether it is warm or cold (see overview of device variants).
  • An analysis of the environmental conditions prevailing where the chiller system is to be installed is also carried out. For example, there might be high temperatures and contaminated air indoors, while outdoors the temperature might fluctuate widely. Both of these factors can have an impact on the configuration of the chiller system, making accessories such as filter fans or crankcase heating necessary. Taking the temperature of the cooling medium at the inlet and the highest likely ambient temperature as a basis, Pfannenberg determines the best chiller model with the correct characteristic curves for the job.
  • The final stage in the application-specific configuration is to think about whether the selected standard version meets the other requirements of the application, such as performance data, control and regulation options, available space, certifications and color. It is then decided whether standard options are necessary or helpful and if so, which. With numerous available options available, the EB chillers meet the requirements of practically any application in industrial environments.

Pfannenberg offers installation-ready chiller systems with performance specifications ranging from 1 to 160 kW. The modular concept of the EB series allows users to select from up to 30 standard options. These include hydraulic bypass/relief valves, flow monitors, tank level monitors, air filters, air filter monitors, check valves, solenoid valves, single alarm display and UL certification. Special solutions are also available. Click here to determine the correct chiller for your application!


With products that include filterfans, heaters, industrial air conditioners, air to water heat exchangers, packaged chillers, and signaling devices, Pfannenberg offers a full range of thermal management solutions for all types of industries. Standard options such as stainless steel materials, NEMA 4/4X enclosures, and washdown duty construction allow these time-tested products to be seamlessly incorporated into even the most demanding applications.

Have a question regarding which equipment is best for your application? Ask Us Here.

Liquid Cooling For Induction Heating Processes

Using Chillers to Ensure the Maximum Cooling Capacity in the Smallest Possible Footprint

Traditional metal working practices are time consuming and inefficient. Heating equipment takes a lot of time and therefore also uses a lot of energy. The removal of heat is also necessary, however, in order to maintain structural rigidness as well as to solidify material in the welding process. Additionally, equipment designs need to ensure it is serviceable. Equipment requires frequent physical contact for maintenance. Safety is also a huge concern with traditional welding or heating processes.

Using Chillers in Induction Welding Processes

Convection alone cannot adequately maintain an acceptable operational air temperature when the ambient air temperature is very high. Therefore, an air-cooled liquid chiller is ideal for removing concentrated heat from process equipment. Induction solves many of the stated problems because it generates heat from within the object instead of an external heat source, saving energy and making it safer to use. Automated induction longitudinal welding is a reliable, high-throughput process.

Factors to be considered when choosing a system for cooling an induction process include cost, space availability, existing utilities, energy and water usage, equipment location, potential for freezing, reliability, and maintenance.

A smart controller in the cooling system will set the minimum and maximum water temperature with an alarm. Plus, a flow switch will trigger an alarm if the flow is too low, protecting equipment from being cooled. In addition, it will have a non-ferrous tank and piping to reduce corrosion and a thick powder coating on the stand-alone chiller, and reliable, easy-to-read fluid indication level readout.

Pfannenberg Packaged Chillers: Closing the loop for Industrial Fluid Cooling Applications

By using the proper temperature setting points, operators improve performance and increase the lifetime of devices. Highly efficient cooling technologies generate cost savings and preserve electrical equipment. Pfannenberg Inc. specializes in just this type of technology. Their air-cooled liquid chiller is ideal for removal of concentrated heat from your process equipment. Operators want to select chillers that have a small footprint for equivalent capacity which is offered in Pfannenberg Inc.’s product lines as well.

 

 

 

 

 

 

 

Pfannenberg’s chillers guarantee a central and economical solution and perfectly meet the need for precise temperature control and absolute reliability. Whether it is a compact or large chiller, maximum cooling capacity in the smallest possible footprint is guaranteed thanks to the heavy-duty micro channel condensers that offer high efficiency and long service life in hot, corrosive, or dirty ambient environments.

Click here to contact our Liquid Cooling Experts!

Pfannenberg Liquid Cooling Solutions for Industrial Electronics

Sealed enclosure cooling solutions ideal for extreme indoor or outdoor environments

Lancaster, NY – Pfannenberg, Inc., a leading global manufacturer of thermal management and signaling technologies, highlights its high-efficiency liquid cooling solutions for industrial electronics. Pfannenberg EB 2.0 Large Packaged Chillers and PWS Series Air to Water Heat Exchangers provide contaminant-free, cost-effective component cooling without adding heat to the local environment.

Closed-loop liquid cooling efficiently and economically improves performance for advanced manufacturing processes and electronics in hot, dirty environments using field-proven water circulation technology. Designed to guarantee full separation of water lines and airflow paths, Pfannenberg liquid cooling systems feature integrated electronic thermostats and flow control components for accurate temperature control and superior energy efficiency. Liquid cooling offers an ideal cooling solution for spindle motors and automation drives in automotive manufacturing, power plant electronics and solar inverters in energy production, and oven controls and product coolers/dryers in pharmaceutical production, as well as for paper & printing, plastic manufacturing, and water/wastewater applications.

EB 2.0 Large Packaged Chillers

Compact Pfannenberg EB 2.0 Large Packaged Chillers allow maximum cooling capacity in the smallest possible footprint. Heavy-duty finned-tube condensers deliver high efficiency and long service life in hot, corrosive, or dirty ambient environments.

Models range up to 30 Tons, so proper capacity is available for most applications, while all units are ready to use after simple installation—requiring only piping and power. Remote start/stop capability and insulated vented polypropylene reservoir tanks for rapid heat load changes provide reliable and flexible operation.

 

Check out Pfannenberg’s EB 2.0 Large Packaged Chillers Presentation Video

 

 

PWS Air to Water Heat Exchangers

PWS air to water heat exchanger

Pfannenberg PWS Air to Water Heat Exchangers deliver energy efficiency and high cooling capacity with a maintenance-free design for indoor and outdoor applications. Featuring a closed-loop design, PWS Air to Water Heat Exchangers seal contaminants out by isolating ambient air from the internal air circuit.

These units are ideal for extreme environments such as plant washdown areas, and areas with high amounts of particulate, high ambient temperatures, or an oily or aggressive atmosphere. PWS Air to Water Heat Exchangers maintain a UL Tested NEMA Type 12/3R/4 seal against enclosure, and a stainless-steel option offers NEMA Type 4X protection.

 

If a water source is not available on site, facilities can combine Pfannenberg PWS Air to Water Heat Exchangers with Pfannenberg EB 2.0 Large Packaged Chillers for an efficient closed cooling solution.

Visit the EB 2.0 Large Packaged Chillers page and the Air to Water Heat Exchangers page to learn more.


About Pfannenberg

Established in 1954 by Otto Pfannenberg in Hamburg Germany, Pfannenberg is recognized as a leading global manufacturer of thermal management technologies within the Electro-technology Industry. In 1958 we invented the Filterfan®, which continues to be recognized worldwide as a leading product to help manage the temperature in electrical enclosures. Our business philosophy: Protecting Man, Machine and the Environment.

Reliable Enclosure Cooling for Commercial Bakeries

Customer Requirement

Pfannenberg worked with a bakery end user to develop a cooling solution for their control cabinets.  Most of the OEM equipment installed in the bakery called for air conditioners to cool the drives. PLCs and additional electronics. Most times Cooling units can be a convenient and effective method for cooling electronics, except when located in dusty, humid areas within the plant.

These AC units failed regularly and had to be replaced. This was not a sustainable solution as the customer had constant issues with clogging coils and overheating panels.

Once a panel overheated they had to either: not operate the machine, or operate the cabinets with the doors open. This would let all the contaminants that were hurting the AC units into the cabinet, damaging the drives and other components.

The Pfannenberg Solution

To use the chilled Glycol that was already present for other machine processes to provide the cooled liquid source for our PWS Air to Water Heat Exchangers.

The solution included:

  • A reliable cooling solution designed for harsh environments
  • Reduced maintenance.  Once installed the units only have just one moving part, so regular maintenance is not necessary
  • Eliminating equipment failures, means greater uptime
  • Reduced energy costs with the PWS units
  • UL Tested NEMA Type 4/4X – washdown

Customer Benefits

Pfanneneberg’s PWS Series Air/Water Heat Exchanger was the precise solution for the problems our customer experienced. Incorporating Air/Water Heat Exchangers improved performance, reduced maintenance, was energy efficient, and prevented unplanned repairs.

 

The 6 Step Guide to Choosing the Best Chiller for your Application

Heat is a single common by-product of today‘s manufacturing machines that include the advanced automation technology required for both high speed operation and high precision. Components such as spindle motors, variable frequency drives, laser and x-ray sources all require cooling to operate properly and reliably – most often in the very adverse manufacturing environments.

With manufacturing space at a premium, machine packages have become smaller and liquid cooling has emerged as the most efficient and economical means of removing process heat. Liquid cooling is especially well adapted to hot, dirty environments, where it provides a method of removing the heat from the machine and not contributing additional heat back into the environment.


A quick guide to choosing the correct chiller:

As each industrial environment is different, Pfannenberg designed a 6-steps guide to help you select the proper chiller for your application:

Step 1: Determine the Heat Load

It is important to determine the heat load of your application to ensure the chosen chiller is big enough for the intended application.There are several ways to determine the heat load (in BTU) but understanding the process is essential to calculating an accurate heat load.


Step 2: Determine the Coolant Type, Temperature & Flow Rate

When the heat load is known, the next step is to determine the coolant, its target temperature and the flow rate that the chiller must provide to the process. This is determined by the method from which the heat is transferred from the process to the coolant and the type of coolant being used. For example, water has different characteristics than oil.


Step 3: Identify Installation Environment

In what environment the chiller will be installed? Indoor applications for example can see high temperatures and dirty atmospheres, while outdoor installations can experience both low and high ambient temperatures. This can effect chiller sizing and require accessories such as air filters, sump heaters, etc.


Step 4: Use Chiller performance curves

Now use the chiller performance curves available to select a chiller model that meets or exceeds the required capacity based on the chilled water supply temperature and the highest expected ambient air temperature. Consideration should be given to the safety margin of the application with respect to available frame sizes to maximize the value of the chiller selection. Find all Pfannenberg Chillers Performance Curves on Thermal Management Catalog.


Step 5: Check Pump performance curves

Check the pump performance curves available to ensure that the pump will provide enough pressure at the design flow rate to satisfy the application. Some liquid cooled systems have small coolant flow paths or longer distances that can have higher than average pressure losses.


Step 6: Final Selection

Finally, consider that the remaining application requirements such as power characteristics, control options, footprint, agency listing, color, etc. are met by the selected standard Pfannenberg chiller. Choosing a standard chiller will bring you greater reliability, easier service with common spare parts and global support.

>> Click here to download the PDF version of this guide.


Pfannenberg offers a versatile range of packaged chillers, ranging in sizes from less than ½ Ton to 30 Tons insuring the proper capacity available for most applications. These packaged chillers are ready to use requiring only piping and power to install as part of your solution for process cooling applications – we‘ll even provide the coolant. Ethylene & Propylene Glycol coolants, with proper corrosion inhibitors are available in a variety of packaging options – both full strength and pre-mixed. Each chiller model includes the pump, tank, refrigeration system and controls required for simple installation and reliable, efficient operation.

Our knowledgeable applications staff is always on hand to discuss the application and to make sure that a proper selection is made. With our many available equipment options we can easily customize our standard chillers to meet specific application requirements.

Contact our engineering team for more information!

Pfannenberg’s Chillers Keep Chocolate Tasting Great


Pfannenberg’s Chillers Keep Chocolate Tasting Great

Chocolate plays a major role in many of our holidays as Valentine’s Day or Easter! Whether it’s a box of chocolates or Easter eggs filled with various sweets – there is an extensive process that goes into making these enjoyable treats!

The manufacturing process of chocolate is a delicate procedure. Temperature control of the equipment and the product is important to producing a flavorful and scrumptious chocolate. All processes related to making chocolates are temperature regulated.

A major aspect of chocolate manufacturing is the conching step. Pfannenbergs’ packaged chillers are an ideal solution for the temperature regulation in this process.  Conching is the step in which the chocolate receives its flavor and smooth characteristics! At this stage, the addition of other ingredients is introduced as metal mixers/rollers mix the ingredients together.  This step generates its own heat, which is integral to keep the flavor and the proper consistency of the liquid state.  This chocolate has to be kept at average of 175°F throughout the process (temperature will vary depending on the type of chocolate).  The length of this process will vary depending on the flavor of chocolate.  Typically the average time spent conching is between 4-6 hours; gourmet chocolate brands will spend 30+ hours at this stage.

Following conching, the next step in the process is tempering.Tempering gives chocolate a distinctive shine and color; adding additional flavor.  It is crucial to have strict temperature control.  For tempering, a cooling tunnel is used to take the ambient air; cooling the air to approximately 50°F.  The air then needs to be heated to ambient air temperature.  Pfannenberg’s process chillers have been used successfully in the production of candy and chocolate.  At this stage it is crucial once again for strict temperature control.  If the temperature of chocolate begins to harden and then is heated to become a liquid state – the chocolate is ruined. For chocolate to receive its distinct flavor, look, and texture – the temperature of the chocolate and the air it is produced in is critical.

Next time you eat a piece of chocolate, be sure to appreciate the process it takes to produce such a sweet indulgence!

>> Click here to discover our complete range of chillers!


About Pfannenbrg…

By keeping electronics in enclosures from overheating, Pfannenberg provides an invaluable service to companies, keeping their machinery and processes consistently operating.  By developing and producing products which are designed to save energy and other resources, Pfannenberg operates by their business philosophy – Protecting man, machine and the environment.


Topics: Cooling UnitsNorth AmericaPackaged ChillersFood & BeverageChillers

Pfannenberg EB Chillers: Tailor-made Solution for a Rail Component Manufacturer


Customer Requirement

A rail component manufacturer needed a solution to eliminate downtime caused from the overheating of their track drilling unit.  The current system used 2 undersized chillers, unable to keep up with the cooling requirements, especially when the ambient temperatures in the plant rose due to the hot afternoon sun.

The Pfannenberg Solution

An analysis carried out on location with the customer revealed that the cooling capacity of the two chillers no longer corresponded with the current requirements.  The cooling system needed to be redesigned.

Taking the temporarily intermittent high ambient temperature in the factory into account, the choice fell on our high performance EB 90 chiller.  This unit has an integrated control module which allows for precise temperature control of the cooling medium.EB_Chiller_drawing.jpg

The solution excels due to:

  • Separate cooling and hydraulic circuits
  • Control module to program small hysteresis of the oil temperature
  • Use at ambient temperatures of up to +40°C
  • Sturdy steel housing with thick powder coating

Customer Benefits

As a result of our plant audit, the customer was able to invest in a new solution that was tailor-made to meet their current needs instead of spending money on a temporary, expensive and insufficient repair of their old chiller system.  The new solution ensures the desired machine uptime even during those days affected by the hot sun.  A new maintenance contract was signed to support the optimum functionality of the equipment for the long term.


Have a question regarding which equipment is best for your application? Contact our engineering team for more information!


Pfannenberg, Inc. is a global manufacturer of Thermal Management, Liquid Cooling Solutions and Signaling Technologies.

Pfannenberg is proud to provide solutions as a single source to its customers. Our business philosophy – Protection for man, machine and the environment.