Heat can easily become the enemy in small and large-scale manufacturing processes.
The Importance of Industrial Cooling
Increased heat in industries can be catastrophic as it decreases the productivity and quality of the process and becomes a health concern for the employees. In the pharmaceutical and food industry, a slight change in temperature can destroy the entire batch.
The quality of certain manufactured materials decreases with an increase in heat. People cannot work around overheated machinery; it can cause exhaustion and dehydration. The most effective solution to all these problems is installing effective industrial cooling systems. They will help regulate the internal temperature as well as the temperature of machinery.
Understanding the Industrial Cooling Process
Industrial cooling involves throwing out extra heat from the industrial process to maintain a specific temperature or prevent the temperature from rising above a certain limit. The general process works as follows:
- A coolant absorbs heat from the industrial process.
- This heated coolant is then cooled down to reuse or thrown out, and new coolant takes its place.
- The refrigerated coolant is recirculated, or a new coolant is added as and when required to regulate the temperature.
But if you take a deeper look, there are two main types of cooling processes, viz., open-circuit and closed-circuit.
In an open-circuit cooling process, a coolant is passed only once through the system. When it absorbs heat, it is thrown out into the environment and replaced with another batch. This kind of process is used mostly in power plants.
Whereas in a closed-circuit process, the coolant is reused in a closed loop. When it absorbs heat, and itself gets heated, it is cooled down using a secondary cooling system and passed again to absorb heat. You’ll find such systems in manufacturing units.
Types of Industrial Cooling Solutions
There are several types of industrial cooling solutions. We at Tempcon focus on:
Each of these serves the same purpose of process cooling and dehumidifying the environment. But they have different working principles. The table below will give you a better idea of how they differ from each other.
| Type | Working Principle | Applications |
| Industrial Chillers | Use a refrigeration cycle to remove heat from a fluid | Food and beverage processing, pharmaceutical manufacturing, and data centers |
| Panel AC’s | Blow air over an evaporator coil to cool and dehumidify the air | Control rooms, server rooms, clean rooms |
| Industrial Dehumidifiers | Blow air over a desiccant to remove moisture from the air | Warehouses, food processing plants, electronics manufacturing plants |
| Grain Chillers | Use a refrigerant to remove heat from the grain | Grain processing units, graineries, poultry food processing units, breweries |
| Precise Air Conditioners | Use a closed-loop refrigerant to cool and dehumidify air | Electrical panel rooms, sortex cabins, server/UPS rooms |
Advantages of Industrial Cooling Systems
The following are some of the common advantages of cooling technology for industries:
- Reduced equipment wear and tear
If industrial equipment constantly operates at high temperatures, they wear out earlier than expected. This can be prevented by installing cooling systems that will keep the temperature in check and maintain the health of the machinery.
- Enhanced safety
High temperature is a safety hazard in many manufacturing processes. It also affects employees’ well-being. By using chiller units, you can reduce the heat of a process and thus enhance safety. It will create a cooler and safer working environment for all employees.
- Increased efficiency
Heat lowers the efficiency of a few industrial processes. By maintaining a certain temperature range, you can expect optimum efficiency in a few industries. So, with proper cooling techniques, you can increase process efficiency by keeping the temperature in check.
- Environmental benefits
Cooling systems ensure that the consumption of water is minimized in some cases and the release of greenhouse gasses is decreased in others. This reduces the negative impact on the environment. Some cooling systems are specially designed to align with sustainability goals. They reduce the impact caused by overheating on the environment.
- Reduced Downtime
Effective cooling systems can maintain the temperature of your machinery and thus completely eliminate machine breakdown due to overheating. This reduces the time wasted in getting the machine to cool down and function again. Thus reducing the overall downtime of the industrial process.
- Increased product quality
Certain products need an environment with a specific temperature. To ensure that their quality is not compromised, cooling systems can help maintain that specific temperature range. This is really important in industries like food and beverage processing, pharmaceuticals, and chemicals
Common Applications of Industrial Cooling
Industrial cooling systems have a wide range of applications. The common ones are:
Grain storage and processing: Industrial grain chillers maintain the temperature and humidity within grain storage containers to keep grains free from mold and fungi. In processing units, chillers are used to cool down grains to the desired storage temperature.
Food and beverage processing: Cooling systems are needed during the processing, storage, and transportation of food and beverages.
Pharmaceutical manufacturing: Manufacturing machinery and the process itself in the pharma industry need heat regulation to ensure the quality of products.
Chemical processing: Several chemical reactions need temperature regulation. Laboratories employ small-scale methods, but industries need proper cooling equipment.
Electronics manufacturing: Many electronic equipment have a defined operating temperature range. If the temperature exceeds the limit post-manufacturing, the equipment will fail before being shipped out.
Power generation: Condensers are used in thermal power plants to convert gases to liquids by cooling them. But even these condensers require cooling to prevent overheating. So, a secondary cooling system is installed for the condensers.
Factors to Consider When Choosing Cooling Solutions
All cooling systems don’t have the same effect. Each has its own set of pros and cons. So before choosing a cooling solution, one should evaluate whether it’s the right choice for their industry. The following factors are essential parts of the said evaluation:
- Type of cooling solution
There are different types of cooling solutions, each suitable for different processes. For instance, a panel AC is the right option for server rooms, whereas a cold drink manufacturing plant will need chiller units. So, choose the right type of cooling technology as per the needs of your industry.
- Space availability
Some process cooling systems require more space than others. So, evaluate the available space for installation before deciding which solution to employ. So you can get the one that will fit into the available space without having to make significant adaptations.
- Resource availability
Cooling systems require access to resources like water, electricity, wind outlets, etc. It is important that you consider the availability of these resources before settling on a cooling solution.
- Operating temperature range
Different cooling systems have different operation temperatures. Certain industries need temperature control within a precise range. Ensure that the solution you choose can operate effectively in the design operating temperature.
- Maintenance requirements
Some cooling systems require more maintenance than others. So, if you are extremely sure that you can handle the maintenance requirements, then go for a high-maintenance system. Otherwise, you can opt for a solution that has low maintenance requirements and costs.
- Budget
This might just be the most important factor of all. You need to finalize your budget before looking for cooling solutions. Keep some wriggle room in the budget so you can buy the one with maximum efficiency but within the desired price limit.
Future Trends in Industrial Cooling
All cooling systems don’t have the same effect. Each has its own set of pros and cons. So before choosing a In today’s market, industrial cooling uses traditional cooling techniques. Some offer innovative solutions, but they still run around conventional techniques.
But in the future, one can expect to see a revolution in cooling technologies. Engineers are working on creating efficient IoT-enabled or AI-powered cooling systems that will learn the environment they are based in and operate automatically without human interference.
Researchers are also looking for more sustainable and environment-friendly ways to employ cooling solutions. They are doing so by using eco-friendly and natural refrigerants like ammonia and carbon dioxide.
Conclusion: Embracing Efficient Industrial Cooling
Industries of every scale need efficient cooling systems to improve efficiency, reduce manufacturing costs, maintain the quality of products, and ensure employees’ safety. Industries need to pause to reevaluate and rethink their cooling needs.
With changing times, employing more efficient and environment-friendly cooling solutions will bode well for the company. Tempcon can always assist you in choosing the right cooling system for your industry. Reach out to us and get in touch with one of our executives, who will answer all your questions.
