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Air Chiller Unit-An Ultimate Buying Guide by TopChiller.

For some industries, temperature control can be a matter of your machine tool service life.

In these types of industries, the heat content needed to be maintained under a specific range so that your process can run without any hindrances.

Improper handling and control of the temperature ranges in these types of industries can jeopardize the whole process, economy, and quality of the product.

For these types of industries, choosing it is one of the most necessary jobs. Choosing a proper Air Chiller Unit can save you money, resources, time, and energy.

Apart from these savings, the all-over quality of your process and product is maintained that affects the reputation of your industry in the market.

An Air Chiller Unit is an air-driven industrial chiller that is used to decrease, and maintain the surrounding temperature of an area in the industry.

The below article is a comprehensive piece of research-based knowledge about an Air Chiller Unit.

What is an Air Chiller Unit?

It is a prominent type of industrial chiller. An Air Chiller Unit is used worldwide in a wide range of applications.

A basic function of it is to extract the surrounding heat of an area and pull it out so that all over temperature can be maintained to the feasible range.

As an Air Chiller Unit discharges heath from the backside, it is usually preferred in the type of industries where heat discharge is not a problem.

It is not only used to cool down the temperature of an area.

It provides a feasible temperature for an area, where machines and people can work harmlessly with any problem of excessive heat.

In this modern era, an Air Chiller Unit is the preferred choice of every industrialist due to its innovative and unique features.

It is easy to install, easy to run, and gives you desired chilling efficiency. Around every industry is preferring an Air Chiller Unit for its plants.

Some of the major industries, where it is used are metallurgical industries, pharmaceuticals, medical industries, power generation plants, etc.

Air Chiller Unit Designed by TopChiller

Why Air Chiller Unit is Important for Industries these days?

In every industry several parameters of an industrial process needed to be controlled. One of the most harmful by-products of an industrial process in the production of heat.

This heat production if not controlled can cause harmful effects on the process, machinery, and the people working around.

This heat when not controlled can cause the failure of the instruments. It can cause a wide range of illnesses to workers, ranging from simple headaches to death in extreme cases.

This excessive heat also contains fire hazards that can destroy the industry and its resources.

To avoid all the above problems, proper arrangements for heat control are necessary for every industry. this is where an Air Chiller Unit becomes vital for industry.

It controls this and regulates this heat content so that your process can run smoothly.

This temperature control has several other benefits too in terms of money, time, workforce, and energy.

Due to these several vital reasons, an Air Chiller Unit is necessary for the concerned industry.

Air Chiller Unit is Used for Temp Regulation in Different Industries

What are the Features of an Air Chiller Unit?

The selection is made based on its features. These unique features are the ones that make your process more efficient, easy, and beneficial.

An Air Chiller Unit contains several features that make it unique and preferred for everyone. Below mentioned are some of the most beneficial features.

1. Economic Device:

An Air Chiller Unit usually costs lower than any other chiller or cooling device. This cheaper cost does not come at the price of chilling efficiency.

It gives maximum and desired efficiency at this low cost.

The economic cost of an Air Chiller Unit allows you to save a lot of capital money that can be utilized for other purposes in the industry.

2. Very Easy to Install:

Installation of any device requires a workforce, time, energy, and money for expert help. An Air Chiller Unit is easy to install.

All you have to do is to go through the installation manual provided by the manufacturing organization and you can easily install it by yourself.

With some simple steps and precautions, you can install your Air Chiller Unit in a short time. It will save your time, money, and workforce.

3. No Cooling Towers Are Needed:

There is no need for a separate water tower to run an Air Chiller Unit, like a water-driven chiller unit. A water cooling tower requires a lot of money and time to construct and run.

Apart from money, operating and cooling water requires effort and time. It is a huge benefit of using an Air Chiller Unit that you are saved from installation and managing a cooling tower.

4. Reduced Water Wastage:

It does not need a huge amount of water to operate and provide chilling.

It requires a minor amount of water, hence saving your water and money spent on the water. Apart from the money, you can save a huge of water from getting polluted.

Polluted water treatments require extra capital and all over process cost is increased.

5. Eco-Friendly:

An Air Chiller Unit is the type of device that produces less amount of air pollution. Like all other refrigerators and chilling devices, it does not use any of the chemicals for chilling.

In this era having an eco-friendly device is desired by every industry and customer. An Air Chiller Unit creates a minimum of the degradation of the environment.

6. Easy and Cheap Maintenance:

The Maintenance of an Air Chiller Unit will increase its efficiency or maintain its efficiency at the maximum chilling efficiency.

Usually, maintenance of any device requires a lot of capital money, and time to maintain. From small to big repair and techniques are used to keep your device properly maintained.

You can easily maintain your Air Chiller Unit in a short time and less amount money spends on it.

7. Easy to Operate and Run:

Operating and running an industrial device for any process is a tough job and requires an expert team of experts people around.

As the proper running of a device is vital for the success of every industrial process. Running an Air Chiller Unit is very easy, after its successful installation.

Operating it requires you to follow a set of simple instructions. Anyone with short training in the start can easily and properly manage and operate an Air Chiller Unit.

8. No Hazardous Chemical is Used:

There is no chemical needed to run it properly. This makes an Air Chiller Unit a clean device.

These features can save a certain amount of money and also keep your industry and process clean, chemical-free.

9. Space Saving:

In industries, where space is a problem IT can be a good choice as a chiller.

Usually, an Air Chiller Unit comes in a moderate size range and can fit in a small space around.

This makes you save a lot of space and more design options. Saved space can be utilized for several other useful purposes.

10. Its Durable And Long-Lasting Device:

All the components of an Air Chiller Unit are made of high-quality materials. These materials are highly durable and will keep them healthy for a long time.

If maintained carefully, it can last longer than a decade.

11. A Corrosion-Resistant And Rust-Resistant Device:

All the parts of an Air Chiller Unit are made of metals and plastics, with some exceptions for other materials. Most of the metal is stainless steel.

This high-grade stainless steel makes it free from corrosion, rust, and other types of chemical attacks.

Stainless Steel Body Air Chiller Unit

What is the Working Principle of an Air Chiller Unit?

It works on the simple process of heat absorption and heat extraction.

An Air Chiller Unit, first of all, pulls in all the heat of the surroundings, and the excessive heat is pushed to space behind it.

This simple process involves a lot of complicated mechanisms inside. In the end, the heat content is dropped to a certain temperature that is desired by the industry.

The cooling cycle of an Air Chiller Unit is beginning with the start of the evaporator. An evaporator contains a set of tubes, that contain liquid refrigerant inside them.

This refrigerant circulates in the tube assembly. During this circulation, the heat content of the environment is extracted and converted to vapors.

These vapors are managed by the compressor. After the production of vapors, a compressor pulls the vapors to the next part, which is a condenser.

In a condenser, the pressure and temperature are given rise to a certain level.

This whole cycle ends when the final liquid with high pressure is pulled out with the help of expansion valves, or expansion devices.

The whole cycle is repeated again and again to produce more chilling. No repetition for a cooling cycle depends upon the requirement of the concerned industry and process.

Air Chiller Unit Vapor Compression System

What are the Major Components of an Air Chiller Unit?

The most common and major components of an Air Chiller Unit are; a compressor, a condenser, evaporator, expansion device, etc.

1. The Compressor:

A compressor is the most important component of an Air Chiller Unit. The major function of a compressor is to circulate the liquid refrigerant in the tubes, and tube assembly.

The compressor performs the first step of the cycle; hence the success of the cooling cycles highly depends upon the proper functioning of a compressor.

2. The Condenser:

A condenser is the second most important device of an Air Chiller Unit. A condenser is composed of a set of pipes, also called tube assembly.

Refrigerant after passing through a compressor passes through the tubes of the condenser.

3. Fans of Condenser:

When a refrigerant is passed through a condenser, the air is passed through tube assembly to lower the heat content of the liquid.

This air is provided for the fan or set of fans, called Fans of Condenser. Condenser fans are the major component that differs an Air Chiller Unit from a water chiller unit.

4. Expansion Device:

An expansion device is also called a valve of expansion or expansion valve. The major function of an expansion device is to convert refrigerant liquid to vapor form.

These vapors are passed and moved to the evaporator. Apart from converting the form of refrigerant, an expansion device also controls the amount of refrigerant that is to be converted.

5. The Heat Exchanger Device or an Evaporator:

An evaporator is the last component of an Air Chiller Unit and performs the last function.

The major role of a heat exchanger is to create low-temperature cooled water that will be passed to the condenser for the final blow of chilled air.

A heat exchanger is located precisely towards the low-temperature side of an Air Chiller Unit.

6. Filter Assembly:

A filter assembly is made of a single or set of filters. These filters are important as they keep other components of an Air Chiller Unit safe and sound from external contaminations.

They block dust, moisture, and other contamination from entering the internal system of an Air Chiller Unit.

Air Chiller Unit Branded Compressor

What are the Applications of an Air Chiller Unit?

It is used in industries like; food industries, chemical plants, solvent and paint industries, metal production industries, and so on.

Some of the major industries, where an Air Chiller Unit is used are given below.

• Cooling of Process Heat:

It is used to cool down and control the heat that is generated in a process in the industry.

This heat can be generated due to various problems like; friction among the tools, chemical reactions, etc.

This heat is needed to be controlled so that process can run smoothly. This heat is also needed to be controlled because, in excessive heat, workers won’t be able to work.

• Polymer and Plastic Making Industries:

Polymer and plastic manufacturing processes require heat as a basic parameter of their process. Almost all plastic manufacturing includes heating and melting of raw materials.

These melted raw materials are poured into the molds and given desired shapes. Temperature control in plastic industries is needed to be highly precise.

The slightest fluctuation can make plastic burn or get solid again.

• Ironmaking and Steelmaking Industries:

The manufacturing of iron and steel is all about controlled heating and controlled chemical reactions.

Steel manufacturing industries are the ones where the highest range of temperature is used to melt metals, solid, and other materials.

In these types of industries, workers are required to work under extreme heat conditions.

An Air Chiller Unit is used to make this extreme hot environment bearable for the worker and the process so that everything can run smoothly and properly.

• Laser Manufacturing Industries:

All the laser industries require cooling as a major part of their manufacturing process. A single Air Chiller Unit or several that can be used to achieve this condition is laser industries.

• Pharmaceutical Industries:

Pharmaceutical labs and industries are the places where highly precise temperature control and cooling conditions are needed.

During the biochemical and biological reactions for the manufacturing of drugs, highly accurate temperature control is needed.

Apart from the process, a highly cooled environment is needed to preserve the products, drugs, chemicals, etc in the pharmaceutical industry.

An Air Chiller Unit is used in pharmaceutical industries, in a highly precise and controlled manner.

• Food Manufacturing Industries:

The most basic principle of food is baking, which is a heat-based process. in food manufacturing industries, huge backing furnaces are installed to produce food in bulk.

The melting and baking operations produce a large amount of heat. This heat control is made possible by the use of a suitable Air Chiller Unit.

Heat control is very necessary for the food industry, as workers are supposed to work in close contact with the baking furnaces, etc.

this temperature control in food-making industries is directly related to the quality of product food.

Air Chiller Unit Applications

What should be considered before buying an Air Chiller Unit for your industry?

Selecting a suitable Air Chiller Unit for your industry is a very important job. Every industry has its desires and goals set about it.

For every industry, several basic factors are necessary to be considered before buying an Air Chiller Unit. These factors are given below in order of their importance.

• The Temperature load:

You should know the range of temperature of your industry and compare its capacity.

Buy an Air Chiller Unit that can overcome your temperature range.

• The Power Requirements:

You should know its power source requirements to work properly. Get an Air Chiller Unit that runs smoothly on the power range.

• Quality Certificate from the Agency:

A lot of agencies around the world provide a standard quality certificate to reliable manufacturers.

Get an Air Chiller Unit from manufacturers with the certification of quality and reliability.

• The Space Needed, and its Size:

The size and the installation space needed by it are important factors.

As these factors will affect the design of the industry, they should be considered and decided before buying an Air Chiller Unit.

• The Flow Rate:

Flow rate and chilling speed are important factors. Consider buying an Air Chiller Unit with a speed that can overcome the heat content with the shortest of the time range.

So that your process can run with optimum speed.

How to Increase the Working Efficiency of your Air Chiller Unit?

Maintaining its optimum working efficiency is necessary to run your process without any problem.

There is a range of practices that can be done to keep it at maximum working efficiency. These practices are discussed below.

1. Lower the Input Load:

Try to lower the heat load of your industry by some means. Lower load with keeping your Air Chiller Unit easy and healthy while performing.

2. Keep the Record of Performance:

Monitor its chilling efficiency and working pattern on daily basis and analyze its shortcomings. In case you find any faulty performance, fix it instantly.

3. Keep it Leakage-free:

Any type of leakage with effect adversely the chilling efficiency of your Air Chiller Unit. Inspect it on daily basis to find any small to big leakage.

Keep it free of leakage and its optimum chilling efficiency will be maintained.

4. Leave Enough Space Around it:

As an Air Chiller Unit extracts the excessive heat from it, there should be enough space around it.

Having space will make heat extraction easy and chilling speed will be increased to its optimum.

5. Keep It Clean:

Regular cleaning should be done of all the small to big components.

A clean Air Chiller Unit will not catch any choking or clogging and will be performing efficiently for a longer period.

6. Get Expert Help and Assistance:

If your Air Chiller Unit efficiency is still decreasing despite doing all the precautions, contact an expert for advice and help.

Follow the instructions provided by the expert to maintain the working efficiency of your Air Chiller Unit to its maximum range.

Air Chiller Unit Leakage Inspection

How to Install your Air Chiller Unit?

Installation of an Air Chiller Unit is an easy job. You can easily install it by following the general instructions provided by the manufacturer.

Some of the necessary considerations for proper installation of an are given below.

Step 1: The first job is to select the proper location of your Air Chiller Unit. The location should be so that proper chilling can be provided to the whole area around.

Step 2: Make selected location ground vibration proof. This can be done with the help of commonly used vibration-proof pads, and rubbers.

Step 3: After the preparations of location and ground setting get it delivered to your industry safe and sound. Make sure not to damage it during delivery.

Step 4: Unpack it’s all parts and check all parts for any failure, or broken parts.

Step 5: Follow the instruction of the manufacturer to unbox the parts.

Step 6: Assemble the parts and start your Air Chiller Unit following the instructions.

Step 7: Connect it to the suitable power sources and start it. Reset the operational parameters and initial setting according to your requirements.

Step 8: Run it for at least 15 minutes before using it for the process applications.

Step 9: Check it working efficiently in these 15 minutes and when you are sure, start your Air Chiller Unit for the process application.

What are the Safety Guidelines for an Air Chiller Unit?

It does not need any complex or hard safety precautions to be considered. Almost all its process is safe and sound.

It is designed in a way that almost all the operations and processes are safe and does not have any potential threat to human safety.

To be on the safe side and to avoid any undesired accident, following safety instructions should be kept in mind.

• Do not wear long sleeves and loose clothes while operating an Air Chiller Unit. Long clothes can get caught and cause an accident.
• All the operations should be handled by wearing a standard safety apron.
• Make sure to use protective glasses to keep your eyes safe from any kind of spill.
• The proper set of PPEs should be worn by all the people working around it.
• Workers should be given proper training before operating an Air Chiller Unit.
• Emergency first adds service should be available all the time in the industry.
• All workers should follow the safety regulations provided by the manufacturing organization.
• Do not get direct exposure for a long time, from the chilled air blow from an Air Chiller Unit. It can make you sick instantly.
• Eating, drinking, and other related activities should be strictly avoided around an Air Chiller Unit.
• There should be no direct touching to parts. All the contacts should be made by wearing safety gloves.
• In case of anything wrong or any threat identified, the worker should immediately report to the plant in charge or the manager available.

Wear PPE Before Air Chiller Unit Operations

What are the Most Common Problems and their Solutions for an Air Chiller Unit?

While operating and running it, you can face several problems.

These problems are generally minor, but if not repaired instantly can cause total failure of your Air Chiller Unit.

Following are some of the common problems and their solutions.

• Excessive Noise from a Fan:

This can be because of choking of fan or power problem. Clean your fan and start it again.

• Low Chilling Efficiency:

The most common reason for this is some kind of leakage in your Air Chiller Unit. Check tubes, and other parts for any tinny leakage and get it repaired instantly.

• Improper Flow Fate:

Flow rate problems are usually because of choking and clogging of the tube assembly. Cleaning tube assembly will solve your problem instantly.

• Reading Meter Does Not Turn On:

This can be because of power problems, or failure of the internal circuit. Contact expert help for this kind of problem.

How to maintain your Air Chiller Unit?

Any kind of unwanted problem can create disturbance to the whole process and cost you a lot of money, time, and resources.

Following given are the instruction that can be followed so that your Air Chiller Unit remains well maintained and healthy.

• Change the Filters Frequently:

Filters of the Air Chiller Unit keep internal parts clean and safe. These filters should be changed over time so that better cleaning can be provided to other parts.

• Keep Filter Assembly Always Clean:

Clean the filter assembly on regular basis before after and after operating your Air Chiller Unit.

It will keep the major components of your clean and it will be maintained for a long time.

• Clean Tubes Assembly:

Tubes of the condenser should be cleaned on regular basis. This will allow smooth flow of refrigerant and maximum chilling efficiency or your Air Chiller Unit will be maintained.

• Check Wiring and Power Source:

The wiring and power source of an Air Chiller Unit should be checked frequently. Repair any small fault, before it creates a big problem.

Wiring repair work is hazardous and should be done by an experienced electrician.

• Have Proper Ventilation Around It:

Ventilation is necessary for an Air Chiller Unit so that it can extract heat easily. Leave a proper space around it, especially on the backside.

Ventilation will facilitate the extraction of excessive heat more efficiently and allover chilling efficiency will be increased.

• Do Not Overload:

An Air Chiller Unit should not be overloaded beyond its capacity. It will break the device and ultimately it will stop working.

Replacement of Air Chiller Unit Parts

FAQ of Air Chiller Unit

Which Component of an Air Chiller Unit is Most Important?

All the components are important in the Air Chiller Unit. The compressor is the most important because a chilling cycle starts from it.

How to Clean your Air Chiller Unit?

Cleaning should be done with proper clothe and cleaner. Select the proper chemical cleaner with the instructions of experts or the manufacturing industry.

What to Do when Filters of an Air Chiller Unit Are Chocked?

Clean the filters immediately with the help of a brush or vacuum pump.

Is Air Chiller Unit Resistant to the Corrosion and Rust?

Yes. An Air Chiller Unit is made of high-grade stainless steel that makes it corrosion-free. It can get corroded from exposure to some acidic chemicals. Avoid exposure to those chemicals.

How Much Waterproof Air Chiller Unit Is?

All the parts of an Air Chiller Unit are waterproof. But, you should avoid spilling water or other liquids for safety concerns.

100% Quality Tested Air Chiller Unit