Process Water Chiller Markets

Parker Zander Hyperchill Industrial Process Water Chillers for the Beverage and Food Market

Beverage & Food

Applications for industrial process water chillers in the beverage and food industry are far reaching and vary greatly depending on application requirements.

Thermal management can benefit beverage and food manufacturers in many ways, including product storage, product stability, production efficiencies as well as special packaging needs.

Examples of common beverage and food industrial process water chiller applications include:

  •  bakery
  •  chocolate - confectionary
  •  soft drinks
  •  wine
  •  brewery
  •  sauces/soups
  •  meat processing (brine)
  •  milk and juice
  •  vegetable and salads
  •  vessel temperature control
  •  cooking systems
  •  steam sterilizing
  •  packaging requirements

Parker Zander Hyperchill Process Water Chillers can provide a complete chiller solution for beverage and food applications, including the use of individual stainless steel, FDA approved heat exchangers for direct product contact or use.

Parker Zander Hyperchill Industrial Process Water Chillers for the Bioenergy Market

Bioenergy

Bioenergy refers to renewable energy coming from biological material such as trees, plants, manure and garbage. Using various transformation processes such as: combustion, gasification and pyrolysis, the bio mass is either transformed into fuels, heat or electricity and used for energetic purposes.

Combustion of biogas, as any other fuel sources, does release some environmental pollutants. But on the whole, biogas is viewed in a positive light from environmentalists. Biogas that is otherwise released into the atmosphere is a significant source of greenhouse gas emissions due to its methane content. Collecting the gas and converting the methane to carbon dioxide greatly reduces the greenhouse gas emissions.

What is biogas?
Biogas is produced when bacteria decompose biological matter in an anaerobic environment (no oxygen present). The decay of biomass produces a gas that can be used as an energy source. It is composed of methane, carbon dioxide and smaller amounts of hydrogen sulphide and ammonia. Trace amounts of other gases like hydrogen, nitrogen or carbon monoxide are also present. The mixed gas is saturated with water vapor and may contain dust particles along with siloxanes.

Why must biogas be treated?
For biogas to be used as a fuel, impurities must be removed as they cause corrosion, deposits and damage to the equipment. Impurities consist of:

  •  carbon dioxide
  •  halogen compounds (chlorides, fluorides)
  •  siloxanes
  •  aromatic compounds
  •  hydrogen sulfide
  •  water

GES Biogas Chilling Systems bring Hyperchill technology to the biogas industry. We bring together the latest technological advances in refrigeration, heat transfer and condensate separation to chill and dehydrate biogas with maximum efficiency at minimum operating cost. Welcome to the cutting edge of biogas treatment technology.

Our custom designed GES Biogas Chilling & Dehydration Systems are the result of more than 40 years of engineering research and development in the field of high quality gas treatment.

  •  Precision Water Chillers
  •  Tube & Shell Heat Exchangers
  •  3 Stage Condensate Separators
  •  Coalescing & Particulate Filters

Choose from our wide range of system components or have us tailor a comprehensive skid mounted chilling or dehydration system specifically for your application.

Parker Zander Hyperchill Industrial Process Water Chillers for the Laser Cutting Market

Laser Cutting

Use of Hyperchill Laser Chillers in the Laser Industry

The laser is the most universal tool available for cutting, welding, marking, drilling, coating, hardening, and performing structural processing work on surfaces. A laser operates without contact, no wear and tear. The heat-affected zone and component distortion produced is extraordinarily small. Refinishing work is usually unnecessary.

The characteristics of cooling systems used to remove heat from lasers are well defined and standardized. Each manufacturer is able to provide the required refrigerating capacity needed to cool the laser head and the optical circuit for their machinery.

The power required usually ranges from 102,364 up to 170,607 BTU (30 up to 50kW) although recently there has been a tendency to increase the power to enure higher outputs for plate processing lines, and to dipose of as much as 238,850 to 272,971 BTU (70 to 80 kW) per system.

The reference temperature for the laser inlet/outlet cooling fluid are 68/77°F (20/25°C). The control must be "exact" with a maximum differential of 2°F (1°C) at every heating load. This absolute differential must also be ensured in the phases of changing plates, with a low heating load or none at all.

Often, de ionized water is used with an anti-passivation agent added. To prevent corrosion or the process fluid contamination, the entire hydraulic circuit must be made of non-ferrous materials (stainless steel, cooper and brass).

Pumps must provide a useful head pressure of 72 psi (5 bar) for the system to overcome the high losses of head that occur in the small distribution pipes inside the laser.

To ensure minimum water temperatures (approximately 68°F (20°C), heating elements are requried for the hydraulic circuit, even when starting up for the first time, with a lower external temperature than required by the laser.

Typical Applications

Cutting
Laser cutting provides a quick and cost effective way to cut most any material (steel, stainless, ABS, acrylic, Teflon, and most all engineered plastics). Laser cutting does not oxidize the cut edges, which is important when welding is the next process step after cutting. Laser cutting is used industrially for materials up to 25 mm thick. Both CO2 and Nd:YAG lasers are suitable for the application, although other technologies such as fiber lasers and high powered diodes are applicable as well. The decision is influenced by factors such as geometry of the cut, cycle time, system technology and, most importantly, the material.

Welding - Laser Beam Welding (LBW)
Laser Beam Welding is a welding technique used to join multiple pieces of metal through the use of a laser. The beam provides a concentrated heat source, allowing for narrow, deep welds and high welding rates. The process is frequently used in high volume applications, such as in the automotive industry. LBW is a versatile process, capable of welding carbon steels, stainless steel, aluminum and titanium. Due to high cooling rates, cracking is a concern when welding high-carbon steels. The weld quality is high, similar to that of electron beam welding. The speed of welding is proportional to the amount of power supplied but also depends on the type and thickness of the work pieces. The high power capability of gas lasers make them especially suitable for high volume applications.

Parker Zander Hyperchill Industrial Process Water Chillers for the Material Processing Market

Material Processing

Use of Hyperchill Process Water Chillers in Material Processing

Forming and shaping processes may be classified into two broad types: those performed on the material in a liquid state and those performed on the material in a solid or plastic condition. Materials in their solid state are formed into desired shapes by the application of a force or pressure. After the material is formed, it is usually further altered. In materials processing, a "removal" process is one that eliminates portions of a piece or body of material to achieve a desired shape. Although removal processes are applied to most types of materials, they are most widely used on metallic materials.

Machining
There are a number of metal-cutting processes. In almost all of them, machining involves the forcing of a cutting tool against the material to be shaped. The tool, which is harder than the material to be cut, removes the unwanted material in the form of chips. Thus, the elements of machining are a cutting device, a means for holding and positioning the work piece, and usually a lubricant (or cutting oil).

EDM
Electrical Discharge Machining and grinding erodes or cuts the metal by high-energy sparks or electrical discharges. EDM typically works with materials that are electrically conductive, although methods for machining insulating ceramics with EDM have also been proposed. EDM can cut intricate contours or cavities in pre-hardened steel without the need for heat treatment to soften and re-harden them as well as any other metal or metal alloy such as titanium, hastelloy, kovar, and inconel.

Water Jet
A water jet cutter is a tool capable of slicing into metal or other materials using a jet of water at high velocity and pressure, or a mixture of water and an abrasive substance. The process is essentially the same as water erosion found in nature but greatly accelerated and concentrated. It is often used during fabrication or manufacture of parts for machinery and other devices. Because the nature of the cutting stream can be easily modified, water jets can be used to cut diverse materials, from prepared foods to metals. It has found applications in a diverse number of industries from mining to aerospace where it is used for operations such as cutting, shaping, carving, and reaming.

Welding
Another further alteration may be "joining," the process of permanently, sometimes only temporarily, bonding or attaching materials to each other. The term as used here includes welding, brazing, soldering, and adhesive and chemical bonding. In most joining processes, a bond between two pieces of material is produced by application of one or a combination of three kinds of energy: thermal, chemical, or mechanical. A bonding or filler material, the same as or different from the materials being joined, may or may not be used.

Surface Treatment
Surface Treatment is a broad range of industrial processes that alter the surface of a manufactured item for achieve a certain property. In limited cases some of these techniques can be used to restore original dimensions to salvage or repair an item. Finishing processes may be employed to modify the surfaces of materials in order to protect the material against deterioration by corrosion, oxidation, mechanical wear, or deformation; to provide special surface characteristics such as reflectivity, electrical conductivity or insulation, or bearing properties; or to give the material special decorative effects.

Parker Zander Hyperchill Industrial Process Water Chillers for the Medical Market

Medical

Use of Hyperchill Medical Chillers for the Medical Imaging Industry

Magnetic Resonance Imaging (MRI)
Primarily used in medical imaging to visualize the structure and function of the body. It provides detailed images of the body in any plane and it has greater soft tissue contrast than CT. Unlike CT, it uses no ionizing radiation.

Advantages:

  •  no ionizing radiation
  •  excellent soft-tissue contrast
  •  multi-planar capabilities
  •  ability to directly acquire volumetric (3D) data
  •  temperature sensibility

Computerized (axial) Tomography (CT) Scanners
This is a scan that takes pictures of a body from different angles and uses a computer to put them together to give a series of cross sections or ’slices’ through the part of the body being scanned. The pictures are taken as the body moves through the machine.

How does a Hyperchill Medical Chiller fit?
Medical scanners use cold water to chill different parts of the system. The specifications of the chiller are typically: 95°F (35°C) ambient, 50°F (10°C) water temperature, non-ferrous hydraulic circuit and nominal 5 bar pump. Hyperchill Medical Chillers combine advanced design solutions, such as energy saving scroll compressors and a sophisticated microprocessor in a complete turnkey process cooling solution to meet the specific needs of medical equipment users. These include Hyperchill Medical Chiller’s extreme flexibility toward the varied working conditions typically found in medical cooling applications.

Parker Zander Hyperchill Industrial Process Water Chillers for the Ozone Market

Ozone

Use of Hyperchill Process Water Chillers with Ozone Technology

Ozone is a three atom molecule that is environmentally friendly and a powerful oxidant. Ozone is suitable in all situations where pollutants and undesirable substances exist without combining with or producing harmful by products. Ozone molecules react quickly and selectively with a large number of compounds which liberate an oxygen molecule. Because Ozone is unstable and very reactive, it cannot be stored and must be produced when and where it is needed. Ozone is produced from oxygen-containing gases in ozone generators by means of a silent electrical discharge. Ozone gas, when dissolved in water or other pollutants, will oxidize anything organic including certain chemicals, solvents and bacteria/viruses. Once ozone has oxidized the undesirable components, it reverts back to oxygen and is considered by the EPA, in most cases, to be "A Pollution Prevention Technology."

Ozone technology is used mainly in potable water, aquariums, pharmaceutical plants, cooling towers, waste water treatment plants and process water.

Common applications include:

  •  Disinfection
  •  Elimination of odors
  •  Oxidizing organics
  •  Taste enhancement
  •  Oxidation of iron, magnesium and sulfur
  •  Breakdown of pesticides and herbicides

Chillers maintain energy level or adsorbed heat which is a byproduct of the electrical input that separates the natural oxygen molecule. It is critical that a constant water temperature is maintained to keep a consistent output or production of ozone.

Filters/dryers are needed to ensure a clean, dry air supply (oxygen) for the ozone generator.

Parker Zander Hyperchill Industrial Process Water Chillers for the Plastics Market

Plastics

Use of Hyperchill Process Water Chillers in the Plastics Industry

Injection
Plastics are melted with heaters and friction and pressed inside mold cavities. Injection is a discontinuous process. Once the mold is full of plastic, the heaters and screw stop and cold water flows, cooling the mold. The product is then "frozen" inside the mold by means of the cold water that flowed through the cooling channels. When the plastic is solid, the mold opens and the piece is extracted. Optimum temperature means short cooling time, increasing quality and productivity. Different raw plastics can be used in the injection process including: polyethylene, nylon, polycarbonate, PVC and PET. Any material used will have specific physical and chemical properties and a different melting temperature. Working temperature (melting point) is around 392°F. The heat load is determined by the quality of raw material injected and transformed in finished product.

Plastics Injected
kg/h x 200 = kcal/h
1 kW = 860 kcal/h
Injection molding machines use a hydraulic oil set to move all the parts: screw, mold and extractors. The oil is moved by a hydraulic pump and it heats up. The system needs cold water to remove the heat load. One third of the electrical installed power must be removed. Each press is characterized by: mold clamping tonage (force necessary to close the mold) and pump motor power (electrical installed power).

Extrusion
This process is used to manufacture plastic products with a continuous cross-section. Pellets are melted and forced out through a die to give final form. The production is continuous and the product is chilled directly using cold water. The heat load is determined by the quantity of raw material fed into the extruder and transformed into a finished product.

Plastics Extruded
kg/h x 250 = kcal/h
The extrusion blow process is used to manufacture plastic bottles such as milk jugs, shampoo bottles, etc. It begins with the extrusion of a parison or tube, using a die similar to that used for making plastic pipes. Process as follows:

  1. Plastic is melted and forced through a circular die forming a hollow plastic tube called a "parison."
  2. The parison is clamped inside a hollow mold and inflated with compressed air.
  3. The plastic cools in the shape of the interior of the mold cavity chilled with water.
  4. The mold opens and the plastic bottle is ejected.

Blown Film
This is one of the most common methods of film manufacture. Blown film can be used in tube form (ie for plastic bags and sacks) or the tube can be slit to form a sheet. The process involves extrusion of a plastic through a circular die, followed by "bubble-like" expansion. The plastic melt is extruded through an annular slit die, usually vertically, to form a thin walled tube. Air is introduced via a hole in the center of the die to blow up the tube like a balloon. Mounted on top of the die, a high-speed air ring blows onto the hot film to cool it. The tube of film then continues upwards, continually cooling, until it passes through nip rolls where the tube is flattened to create what is known as a ‘lay-flat’ tube of film. This lay-flat collapsed tube is then taken back down the extrusion tower via more rollers. On higher output lines, the air inside the bubble is also exchanged. This is known as IBS (internal bubble cooling).

PET
Poly-Ethylene-Thereftalate is the plastic material used to produce beverage bottles. This production is made in two independent steps: injection and blowing. Pellets are melted with heaters and friction and pressed inside the mold cavities. The products are "frozen" inside the mold cavities, using cold water that flows through the cooling channels. Pre-form production is characterized by high productivity. It is an injection process with low water temperature and high water to speed up the cooling effect.

Injection molding machines are a hydraulic oil set to move all the parts: screw, mold and extractors. The oil is moved by hydraulic pump and it warms up. The system needs cold water to remove the heat load. One third of the electrical installed power has to be removed. Each press is characterized by: mold clamping tonage (force necessary to close the mold) and pump motor power (electrical installed power).

With PET blowing, pre-forms are heated and inflated with compressed air. The air forces the plastic against the mold surface. The plastic cools in the shape of the mold cavity. The mold opens and the plastic bottle is ejected. The heat load is given by the quantity of plastic inflated inside the molds.

Parker Zander Hyperchill Industrial Process Water Chillers for the Printing and Graphics Market

Printing and Graphics

Use of Hyperchill Process Water Chillers with Professional Inkjet Printing Systems

When compared to a traditional analog technology, digital inkjet printing systems provide numerous advantages including increased flexibility, more customization and faster change over times. Thus the market is continuing to expand. Many major suppliers of professional printers now have or will soon have products that use this technology.

The emergence of these high speed ink jet printers has presented new cooling challenges whether the technology is based on chilled rollers or UV curing. Under certain circumstances a nitrogen blanket or flush is also required with UV curing.

While UV-LED lamps do not produce the excessive heat which mercury vapor lamps do, they still require thermal management. Correct thermal management of the UV-LED diodes is very important for maximum lamp life and correct power levels. Recirculation water chillers provide a key solution when the need to use the higher UV power and faster cure times on heat sensitive media is the ultimate goal.

Other high speed digital inkjet printing use water cooled rollers. The speed at which the press operates as well as the duplex function once again demand thermal management.

Parker Zander Hyperchill Industrial Process Water Chillers for the Thermal Spray Market

Thermal Spray

Use of Hyperchill-TS Thermal Spray Process Water Chillers for Coatings Engineering

The demands for engineering coatings are becoming more and more stringent. Environmental concerns are also being considered as an integral part of the design process. The thermal spray process is an attractive coating technique as it offers a wide choice of materials and processes that have a reduced impact on the environment when compared to conventional plating processes.

Thermal spray coating techniques allow many problems of wear, corrosion and thermal degradation to be resolved by engineering the surface with tailor-made coatings.

Of these, Plasma Spray and High Velocity Oxy Fuel (HVOF) present unique cooling challenges. The temperatures at which these guns operate require stringent cooling needs. If adequate cooling is not obtained, application quality will suffer, electrode life will be shortened and damage or destruction of the gun can occur.

10 to 30 ton cooling requirements are common for a single gun, depending on type, as are high return temperatures to the process water chiller. These, along with other requirements (such a non-ferrous circuit, high pressure water and external bypass), make selecting a process water chiller for thermal spray applications a unique selection.