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

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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!

Marine Vienney

Pfannenberg’s Chillers Keep Chocolate Tasting Great

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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 Units, North America, Packaged Chillers, Food & Beverage, Chillers

Marine Vienney

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

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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.

Marine Vienney

Need help sizing Chillers? Pfannenberg is here for you!

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Do you have a need for liquid cooling? Do you have an old chiller that needs to be replaced? Are you unsure of your liquid cooling options? We are here to help!

Correctly sizing a chiller is crucial on many points. An undersized chiller will never be able to properly cool your application while an oversize chiller will be inefficient due to excessive power consumption.

To find the best product for your application you can start by referencing our Chiller Sizing Guide, but if this is not enough to help you choose the best option for your application, you can use our new Chiller Quote Request Form. We’ve created this new web form to allow you to easily enter detailed information about your project, connecting you directly with one of our chiller experts.

CLICK HERE TO REQUEST A CHILLER QUOTE

Pfannenberg is your expert source for liquid cooling products and helping you choose the correct chiller. We offer packaged chillers from fractional tonnage to over 30 ton. Need more capacity? We can talk about a modular design using multiple chillers. We can also offer installation and commissioning of your new Pfannenberg Chiller.

>> Click here for more information about Liquid Cooling Solutions!

Marine Vienney

The Future of Food and Beverage Preservation Utilizing Chillers

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High Pressure Processing (HPP) Technology guarantees a longer lasting freshness and high quality taste for products.

With health and wellness trends dominating the Food and Beverage industry, manufacturers are seeking new equipment to help support maintaining their “healthy” quality throughout the supply chain.Fresh fruits, vegetables, raw juices, and meats have a relatively short shelf life.  Since there are no added chemicals to extend the shelf life – manufacturers are looking for new technology to help extend their product life.  HPP Technology was introduced, not only to extend the shelf life of such products but also maintain the fresh taste.

How It Works:

HPP is a cold pasteurization method that takes food (sealed, covered, or bottled) to a high level of pressure (by water) between 43,000 to 87,000 psi for typically 1-3 minutes. Packaged products will be placed inside a container which then is placed into the HPP machine.  Once in the machine it is subject to cold water and high levels of pressure. Such levels of pressure are more than the ocean’s Mariana Trench and various hydraulic systems.

Pfannenberg’s process chillers are an ideal solution for the temperature regulation throughout this process. Such products are placed under cold water pressures that have to be maintained thoughout the HPP proecess. Temperature control is crucial to be able to prevent from the product going bad.

There have been other technologies introduced, but they have not been able to maintain vitamin levels and flavors.

Benefits of HPP:

  • Environmentally friendly – water can be recycled
  • Maintains food quality and taste
  • Avoids the need for food preservatives and chemicals – maintains natural and organic product
  • Extends shelf-life
  • Kills pathogens – such as Salmonella, Listeria, etc.

Ideal for:

  • Juices
  • Salsas
  • Cooked Meats
  • Fish
  • Fruits
  • Vegetables

While foods with a high level of acidity work well with HPP applications, there are some vegetables and food items that cannot be used for HPP because the process does not kill certain pathogens without the use of heat. HPP is environmentally friendly and a natural process that preserve tastes and maintains the quality and freshness – relative to chemical treatments and traditional thermal pasteurization methods.

Click here to discover our complete range of chillers!

Visit Pfannnenberg at ProFood Tech 2017 in Chicago – Booth #1847

Topics: North America, Water Cooling, Food and Beverage, Food & Beverage, Chillers

Marine Vienney

How Pfannenberg Thermal Management & Signaling Solutions Save the Holidays

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Pfannenberg products ensure that manufacturing operations are up and running – especially during the holidays when many manufacturing lines are always online. Read below on just a few example applications on how Pfannenberg supports these product lines and keeps them running.

Candy Canes:

The go-to holiday candy.  As a child, they are passed out and enjoyed by many, and as adults they are necessary for almost any holiday decoration.  This peppermint candy involves very delicate care when being processed.  There are many differences in temperature to heat up or cool down – just enough that it maintains flavor and will not ruin the product quality.  All throughout the manufacturing process of candy canes, temperatures are critical.  At certain stages, the temperature needs to be increased to help form the canes, then at other parts it needs to be cooled so that it can be mixed to perfect flavor and coloring.

The sugar kneading machine is very large and very powerful.  Right after the sugary mixture is heated up and completed its first round of mixing, it is dumped onto a liquid cooling table, where the candy has its flavoring added and mixed. The amber liquid when being first mixed is heated up to around 300°F.  Once being transferred to the kneading machine, this large machine will mix in the flavoring by pushing and folding the candy – slowly cooling the product from its hot temperature. Pfannenberg’s CC Chillers can play a key role in supplying the cool liquid to the table which kneads the candy.  If the table is left uncooled or heated, it will change the look, consistency, and taste of the final product.  Not only is it crucial to have Pfannenberg Compact Chillers to cool the table, it is also import to utilize Pfannenberg’s PWS Air to Water Heat Exchangers to cool the electrical panels controlling the entire process.

Wrapping Paper:

The wrapping of gifts dates back to the ancient Chinese, but here in the US  it hit its popularity in 1917 when Joyce Clyde Hall and Rollie Hall (founders of Hallmark) decided to modernize it. Wrapping paper is a staple item.  When it comes to holidays and special occasions, there are many steps that go into the manufacturing of wrapping paper.

Artists have to create such artwork which is then etched onto copper cylinders that are bathed in a liquid bath of chromium, which galvanizes the copper to protect it from wear and tear.  From here these rolls each have a various piece of the final wrapping paper artwork.  Each color has its own roller. The paper will go through a series of various printers where it encounters the artwork on the copper rolls for the different colors.  These metal rolls need to be highly controlled with temperature.  Too hot or cold could cause the paper to stick to these rolls and cause a paper jam which leads to loss revenue and downtime. As part of a complete solution  Pfannenberg’s CC Series Chillers help to control the temperature to the print rollers and Pfannenberg’s Air to Water Heat Exchangers provide proper cooling for the control equipment operating these large machines. To complelent our full product line,  Pfannenberg’s Signaling products are needed at every stage of the manufacturing process to alert employees of a problem. Pfannenberg’s Signaling Solutions help the employees to be able to hear and see exactly where the problem is occurring (which machine) and what problem is occurring (what action is need).

Wrapping paper leads to the excitement and mystery of the gift. Without the proper cooling and operation of the equipment that are used to produce the paper, it would be difficult to wrap the gifts.  Pfannenberg aids in the manufacturing process of wrapping paper.

Champagne:

The holiday season concludes with celebrating New Years.  New Years is a time to reflect on the past and perhaps try new things in the upcoming year. Celebrations are had with friends old and new, and champagne is typically the drink of choice. One crucial aspect in champagne manufacturing is the inspection and bottling stages of the process. The champagne bottle undergoes many cleanings and inspections prior, during, and after bottling.  Each stage will monitor and check various aspects.  The final inspection step will make sure that the champagne bottle is not cracked or damaged and to check the champagne to make sure that there are not fragments of cork or metal casing. A bright light will shine through the bottles where a machine will scan and take pictures for an employee to monitor/double check that the inspections are all being passed.

Pfannenberg has proven experience in working directly with food and beverage inspection OEMs to provide complete engineering solutions for the cooling of x-ray tubes and the internal cavity of their inspection machines. The Pfannenberg team has come up with a complete solution to utilize a CC Chiller in conjunction with a small PWS Air to Water Heat Exchanger to cool the x-ray tubes and internal cavity.  By combining products and eliminating a compressor based air conditioning unit, the Pfannenberg liquid cooling solution requires less maintenance and is far more cost effective by eliminating dependencies on different competing products and eliminating downtime.

Marine Vienney

Vacuum Turkey Packaging – Thanksgiving Edition

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Tis’ the season – for we have many things to be thankful for this year!  With the holiday season quickly approaching, we are taking the time to reflect on all of our blessings.  Common dishes for most Traditional American Thanksgivings include turkey, cranberry sauce, stuffing, green bean casseroles, fresh baked rolls, and pumpkin pie. Most of us look forward to this holiday all year, for it is a time to be thankful and gather with loved ones.

Turkey processors themselves have to really work all year to meet this spike in demand around the holidays.  Innovation in new packaging technology allows these processors to be able to serve a fresh Turkey that has a longer shelf life without chemicals.  Pfannenberg’s thermal management and chiller products are a perfect fit for aiding in the packaging side of Turkey processing.

Vacuum packaging is the most popular form of packing and food preservation for full turkeys. The process reduces the amount of oxygen from the package by utilizing a vacuum and completely sealing it, removing the extra oxygen to prevent contamination. The removal of oxygen allows the product to have a longer shelf-life. The packaging material protects the meat from the passage of various gases and outside moisture.

When it comes to the vacuum packing machines they operate at very high speeds, processing many turkeys in a short amount of time.  It’s critical that the control enclosure electronics  do not overheat. Proper cabinet temperature control is essential to keeping production on schedule. To keep these electrical enclosures cool, the processing facility has several options. If using traditional enclosure air conditioners (cooling units) then our washdown NEMA Type 4/4x DTS 3000 Series Cooling Units would be a good solution. For a more economical and maintenance free solution our stainless steel PWS Air to Water Heat Exchangers could be used with existing water lines or a Pfannenberg Packaged Chiller. These both would be perfect options to protect the electronics and  drives that are so important to keep everything online and running.

Besides the electronics in the electrical panel, the motors (servo motors) need a chiller to maintain the cool liquids running through the machines.  Pfannenberg’s CC Series Chillers are ideal for quick setup and trouble free operation.  Packaged and ready-to-use, Pfannenberg’s chillers require piping and power to install a solution for process cooling applications.

Pfannenberg’s enclosure cooling solutions and chillers aid in meeting the high demands of poultry processing equipment during the peak season helping to ensure there is not a turkey shortage on the biggest turkey day of the year!

Happy Thanksgiving to you and your family!

Marine Vienney

Pfannenberg – Global Solutions and Support for OEMS

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When it comes down to the final decision on whether or not to purchase new equipment for a plant, the decision tends to fall down to three major concerns:

  1. What preventative yearly/monthly/weekly/daily maintenance is required?
  2. Is it able to withstand the environment?
  3. How much time and money will it save?

For OEMS to be competitve and meet the needs of their end use customers, there are 3 main areas that are looked at when choosing the supporting components for their equipment.

Components that are Built to Last

For more than 60 years, we have been helping guarantee production safety for OEMs and end users throughout the world.  Sensitive control technology needs to be protected from many environmental conditions. With NEMA Type 4/4X, IP 56 protection, our cooling units satisfy the toughest environments.

Support and Accessibility

Pfannenberg innovation has made it one of the largest globally operating manufacturers of thermal management and process cooling equipment today.  Our wide product range includes complete system solutions for machine and enclosure cooling along with visual and audible signaling devicesfor events that require alarm, warning or indication notifications.

Support… when and where it’s needed – In addition to manufacturing facilities location on three continents, Pfannenberg has developed a worldwide network of local subsidiaries and sales/service partners eager to meet your service needs and help you select the correct solution.

If maintenance of your enclosure cooling system is required you can expect immediate assistance from Pfannenberg. Our repair service affords you the fastest possible response – nationally or internationally. We ensure that your cooling system is returned to optimal condition – even if it’s not a Pfannenberg product.  Our on-site service gets you back on-line faster, eliminating the transit time associated with factory repair programs.

Experts in Industry Group Solutions

As a leading thermal management solutions
company, we can develop products quicker than the competition while optimizing the solution for that specific industry group’s requirements. The high performance of our products comes from years of research and design experience. Trust us to be the experts in your industry to provide you  with the proper cooling solution.

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

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Understanding the Different Types of Liquids Used in Chillers for Cooling Processes

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With manufacturing space at minimum, machine packages have become smaller and liquid cooling has emerged as the most efficient and economical means of removing process heat. Chillers often are the only method of providing sustainable efficiency & reliability performances in “hostile” environments.

A chiller uses a refrigeration cycle to remove the collected heat from a circulating liquid. As the liquid moves through a system of tubes and pipes, it absorbs the heat generated by equipment and processes. This generated heat is then transferred by the liquid back to the chiller where it is dissipated. Fluid is cooled and sent back into the system.

>> Click here to learn more about Closed Loop Liquid Cooling Solutions.

But even if you determined that Liquid Cooling is the right solution for your environment, how do you know which heat transfer fluid you should use?

Liquids Used to Cool Your Processes

Pfannenberg process chillers offer different types of liquids to cool your processes as Water/Glycol mix, Water, and Specific Oils. Pfannenberg always recommend to use the water/glycol mixture as it’s the best way to “Protect Man, Machine and the Environment”.

1/ Glycol-Water Mixture

It is recommended to use a Water-Glycol
mix when freeze protection is needed, for example if the chiller is placed outdoors.

Ethylene & Propylene Glycol coolants, with proper corrosion inhibitors are available with Pfannenberg’s Packaged Chillers – both full strength and pre-mixed.

We typically recommend the use of Propylene rather than Ethylene Glycol, even though Propylene has less heat transfer capability, as it is more environmentally friendly and much safer to use.

Using Glycol for indoor applications is also recommended as it deters scale and corrosion in the system and provide some lubrication to the chiller pump while protecting metals. Outdoor applications need more Glycol depending on the maximum low ambient the chiller may see. The addition of Glycol does bring capacity of the chiller down slightly.

The Glycol to Water ratio is different depending on the customer’s coolant temperature needs as well as ambient temperatures being indoor or outdoor applications.

2/ Water

Depending on your installation, water cooling can be a good alternative as it is an economical and energy efficient solution. Water can be used from a local source (city water), but it is recommended to make sure that the water used is not high in mineral content which can cause corrosion or clog fluid channels. To avoid damaging the components, filtration is always encouraged.

 

Other types of acceptable water are: Reverse Osmosis Water (RO) and Dionized Water (DI)

  • RO Water is a purified water where 90-99% of most contaminants are removed but not all ionically disolved substances.
  • DI Water is water that is passed through a DI reaction chamber and has all its ions removed so all the impurities, salts or minerals that can cause corrosion are extracted.

Deionized water can sometimes be requested by customers, but it can still be damaging to certain materials and cause corrosion due to its high purity level. Indeed, due to the lack of ions, the water wants to attract ions from everything it touches. DI systems therefore require acid and caustic for regenerations and a neutralization system – which uses harsh chemicals – for the wastewater.

If highly pure water is not mandatory, RO water is a better option as the filtering process is not as defined as DI water.

In all cases, it is always recommended to contact a water treatment specialist for supervising or performing the installation and operation of water purification equipment.

3/ Oil

Cooling with oil is dedicated to very specific applications in which the process liquid is an oil or an emulsion with a high viscosity. Pfannenberg’s EB Chillers allow the maximum cooling capacity in the smallest possible footprint.

These chillers are designed to handle the oil entering the evaporator at higher temperatures than in typical processes. This solution is mainly used for recirculated cooling of machinery, hydraulics, automation components, etc.

 

 

Properly selected equipment is key to cooling efficiency

Whatever your industry, selecting the best packaged chillers to meet the demanding requirements of your industrial applications can be complicated. For that reason, Pfannenberg designed a 6 step guide to help you select the best chiller depending on your environment, process and type of application.

Click on the picture to open the PDF or use this link!

 

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

Marine Vienney

Pfannenberg Products Assist in Making an American Staple Summer Treat

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Hot dogs – a staple summer treat that brings back memories of family cookouts and baseball games. It is an American favorite summertime food! Hot dogs go through a series of complex processes that combine the ingredients into their delicious final form and Pfannenberg’s PWS Air to Water Heat Exchangers are perfect to keep things running.

Meat Processing

The first step into creating one of the most loved foods is the preparation of the meat.  The meat is cut into small pieces and is placed into a large mixer.  These mixers have chopping blades to further cut the meat into smaller sizes. Here the raw ingredients and flavorings are added.  All are mixed until the mixture is a smooth paste consistency. Processes like this can require large control panels to operate the system and Pfannenberg’s PWS Air To Water Heat Exchangers are ideal for cooling your electrical components. Pfannenberg’s Air/Water Heat Exchangers utilizes chilled water, that is readily available, and an internal fan to provide cool air to prevent critical electronics from overheating.

Linking

The paste is always going through inspections throughout the entire process. After inspection from the mixer – the mix is moved into a stuffer.  This machine will push the paste into tube casings.  The casings are twisted at measured sections to make equally sized hot dogs. There are various casings – natural or artificial. The shaping of the hot dogs we all know is now complete.

Smoking

After the stuffing and linking, the hot dogs are then moved to a smokehouse to cook under controlled conditions.  Manufacturers can control the temperature and the difference flavors that the smoking has on the hot dog by using difference smoke sources.  Average time it takes in this step is an hour.

Final Processing

Once the smoking is completed, the link casings are removed by an automatic peeler.  During this time, the hot dogs are sprayed with water to help bring down their temperature.  Then the hot dogs are then transported to be packaged. Before going into the final packaging, the hot dogs are inspected to make sure there are no foreign ingredients in the product.

Pfannenberg has experience with inspection and x-ray equipment. Pfannenberg was able to combine a Chiller and PWS Air  To Water Heat Exchanger to cool the x-ray tubes as well as the electrical enclosure as one example.

The packaging machines can process thousands of hot dogs in an hour.  They are operating at very fast speeds and require proper thermal management cooling to keep their machines up-and-running. Once packaged, hot dogs are inspected again, freshness dates are added, and they are all boxed up to be transferred to the warehouse for refrigeration until they are shipped. The entire process from start to finish, only takes a few hours.

Click Here to read “Chillers for X-Ray Machines – A Food & Beverage Success Story”.

Be sure to follow our NEW Food and Beverage LinkedIn Showcase Page!