Eliminate the risk of business downtime by investing in an industrial chiller or cooler from Atlas Copco – the world’s leading manufacturer of compressed air systems.
Utilising the most advanced technology, developed in-house by Atlas Copco’s leading engineers, these water-cooling system chillers protect equipment from overheating by cooling process fluids and maintaining precise temperatures in sensitive environments.
Industrial coolers help guarantee a consistent, high-quality end product by ensuring your industrial equipment runs smoothly. They also reduce your energy bills and long-term running costs.
In addition, Atlas Copco’s range of chillers follows the principle of ‘integrated design’, meaning compressors, condensers, smart control systems, fans, refrigerant circuits, and hydraulics are included in one solution. Which means we will have your chiller ready to go in no time at all.
J Ll Leach has been a leading supplier and installer of compressed air, gas, and energy-saving solutions since 1936. As Premier Distributors for Atlas Copco, we can customise the most technologically advanced chillers on the market to suit your specific needs.
Call us today for a no-obligation consultation.
Understanding Industrial Chillers and Coolers
Industrial chillers remove heat from machinery and processes. A Yorkshire brewery uses three 40 kW units to cool fermentation tanks at 4–6°C, while a Birmingham plastics factory maintains injection moulding equipment at 18°C with a 75 kW system.
Most chillers work by circulating water or glycol through heat exchangers. The fluid absorbs heat from the process and carries it to the refrigeration unit. Standard units consume between 0.8 and 1.2 kW of electricity per ton of cooling, depending on age and condition.
Water quality affects performance significantly. A Nottingham electronics manufacturer found their chiller efficiency dropped 8% over six months due to scale buildup in condenser tubes. They now test water hardness weekly and clean heat exchangers quarterly.
Variable speed drives help match output to demand. A Newcastle pharmaceutical plant reduced their chiller energy use by 22% after fitting VSDs to their pumps and fans. The £6,800 installation paid for itself in 14 months through lower electricity bills.
Maintenance requirements include filter changes every 2–3 months, oil analysis twice yearly, and refrigerant pressure checks. Most commercial chillers need a comprehensive service annually, typically costing £600–£900, depending on size.
Temperature stability matters for product consistency. A Manchester food processor monitors chiller output temperatures at five-minute intervals to maintain chocolate production at 17°C ±1°C. Their monitoring system uses standard PT100 sensors connected to a basic PLC controller.
For smaller operations, air-cooled chillers often prove more practical than water-cooled units. They cost about 15% more to run but eliminate cooling tower maintenance and water treatment expenses. Most units under 25 kW are now air-cooled by default.
Common Applications and Industries
Industrial chillers are essential items of equipment in any business that carries out commercial or industrial processes that generate heat and need cooling. Some of the most common uses for Atlas Copco coolers include:
- Manufacturing – Cooling machinery, moulds, and products in industries like plastics, metalworking and electronics.
- Pharmaceuticals – Maintaining a precise temperature while producing drugs.
- Automotive – Cooling test environments and equipment.
- Chemical processing – Controlling the temperature during chemical reactions while guaranteeing a consistent end product.
- Oil and gas – Cooling during the production of chemicals derived from oil and gas.
- HVAC – Providing air conditioning for large buildings such as office complexes, hospitals, and shopping malls.
- Data centres – Cooling servers and other IT equipment to prevent overheating.
Key Features of Atlas Copco Chillers and Coolers
Atlas Copco is widely considered to be the world’s leading manufacturer of industrial chillers that seamlessly integrate with compressed air systems. The brand’s process chillers have been designed with reliability in mind and have in-house-tested, state-of-the-art components.
These cooling systems also comply with the standards set out in the Ecodesign directive 2021, making them some of the most energy-efficient solutions on the market.
To ensure the installation of your industrial chiller causes minimal disruption to your business, all Atlas Copco chillers come with circuits, condensers, compressors, fans, and a superior control system that enables you to safely, accurately, and easily configure your chiller and monitor it remotely. After the quick and straightforward installation, your chiller will be ready to ‘plug and play’.
A Sneak Peek at the TCX Series
We have 15 models of Atlas Copco chillers available with capacities from 4Kw to 90Kw, so you can feel confident we have a suitable solution for your needs. One of our best-selling chillers is the TCX Series, which is a compact, all-in-one water chiller with an air-cooled condenser and integrated hydro module.
The TCX Series features the Elektronikon® MkV Touch controller and SMARTLINK 24/7 remote monitoring. This chiller – along with all your other Atlas Copco equipment, including dryers, air compressors, low-pressure blowers, and nitrogen generation systems – can be covered under one policy.
The Benefits of Industrial Coolers
Equipment Lifespan
Coolers help prevent machinery overheating. A Leeds printing firm found their digital press controllers lasted 2.3 years longer after installing a dedicated 15 kW cooling unit. They previously replaced circuit boards every 12–18 months at £1,400 each.
Temperature logs show that most electronic components operate 8–12°C cooler with proper cooling systems. This falls within manufacturer recommendations, often printed on internal stickers and service manuals.
Product Consistency
Temperature affects manufacturing results. A Sheffield chocolate maker maintains cooling water at 11°C ±0.5°C to ensure proper crystallisation. When their chiller thermostat drifted by 2°C, reject rates increased from 1.8% to 4.6%.
Most food processes need consistent temperatures within specific ranges. Records from quality control typically show temperature variations rather than actual failures.
Power Usage
Modern chillers use less electricity than older models. A Leicester automotive parts supplier replaced their 2005 cooler with a new unit that uses variable speed pumps. Their quarterly electricity costs dropped by £1,740 despite increased production.
Typical energy consumption figures:
- Fixed speed chiller: 0.9–1.2 kW per ton of cooling
- Variable speed chiller: 0.65–0.85 kW per ton of cooling
Most units operate at a partial load 70% of the time, where the biggest savings occur.
Production Continuity
Equipment cooling prevents stoppages. Records from a Manchester plastics factory show they experienced 11 heat-related shutdowns before upgrading their cooling system. In the following year, they had none.
Maintenance logs often reveal a pattern of brief shutdowns that seem random but correlate with ambient temperature peaks or production surges.
Workplace Conditions
Coolers help manage factory temperatures. A Glasgow metalworks uses its process cooling water in heat exchangers to maintain workshop temperatures below 26°C in the summer. They previously lost 2–3 working days annually when temperatures exceeded workplace regulations.
Most health and safety audits include temperature records and staff complaint logs regarding workspace comfort.
Flexible Cooling
Different production needs require adjustable cooling. A Bristol pharmaceuticals facility installed three smaller chillers rather than one large unit. They only run what they need based on which production lines are active, saving approximately 15% on running costs.
The setup required additional pipework costing £3,800 but offered better redundancy. If one unit fails, production continues at 66% capacity.
Environmental Considerations
New refrigerants have less environmental impact. A Coventry food processor switched from R-404A to R-513A, reducing their potential greenhouse gas impact by 56% while maintaining the same cooling capacity.
The refrigerant change cost £1,200 per unit plus labour but helped meet corporate sustainability targets.
Cost Effectiveness
Regular maintenance prevents expensive repairs. Service records from a Hull chemical plant show their twice-yearly maintenance programme costs £1,450 annually but has prevented an estimated £9,000 in emergency repairs over five years.
Most chillers need filter changes every 90 days, refrigerant checks annually, and condenser cleaning based on environmental conditions.
Why Choose J Ll Leach?
J Ll Leach has been at the forefront of our industry for nearly a century thanks to its constant monitoring of the latest developments and its sourcing of the most technologically advanced products on the market from manufacturers such as Atlas Copco.
As Premier Distributors for Atlas Copco, our team of highly experienced and certified engineers guarantees to install your industrial chiller to the highest standards. Moreover, because we operate throughout the UK, we are never far away if you need technical assistance.
Besides design and installation services, we offer routine maintenance and servicing to keep your chiller and compressed air systems running optimally for years, if not decades. We also provide overhaul and refurbishment services to help you get the most from your existing equipment while saving you a small fortune in the long run.
Discover Our Range of Atlas Copco Chillers and Coolers
Whether you need a brand-new industrial chiller installation to accommodate your growing business or just want to upgrade your current solution to reduce your running costs, we have the perfect Atlas Copco chillers and coolers for you. We can design, configure and customise our systems to meet your specific commercial requirements. We can also maintain your vital industrial equipment to help protect your bottom line and get the most from your assets.
If you want to learn more about our range of chillers and coolers, do not hesitate to call us. We will be happy to organise a no-obligation consultation at a time that works with your busy schedule.
FAQ
What makes industrial chillers energy efficient?
Several design features affect efficiency. Variable speed drives save power by adjusting motor speeds rather than running at full capacity. A Birmingham metal finisher saw electricity use drop by 23% after upgrading from fixed speed to variable speed chiller pumps.
Electronic expansion valves provide better control than mechanical ones. They typically improve efficiency by 8–12% by maintaining optimal refrigerant flow rates across different conditions. Most units installed since 2018 include these as standard.
Control systems matter, too. Modern controllers adjust water temperature based on return temperatures rather than just supply. A Glasgow brewery found this simple change saved them £215 monthly on chiller power.
How do chillers help improve product quality in manufacturing?
Temperature affects production results. A Nottingham chocolate manufacturer maintains moulds at 12°C with a tolerance of ±0.8°C. When their cooling system drifted by 2°C during summer, reject rates doubled from 2.1% to 4.3%.
Most manufacturing processes need specific temperature ranges. Plastic injection moulding typically requires cooling water at 15–18°C for proper part formation. Higher temperatures lead to warping and dimensional issues in quality control reports.
Temperature logs often reveal the cause of quality problems. A Swindon electronics firm traced inconsistent circuit board quality to a faulty chiller thermostat that allowed a 3°C daily variation.
Can a chiller reduce business downtime and long-term costs?
Equipment failures are often linked to overheating. Records from a Manchester textile firm show they had seven production stops annually before installing dedicated process cooling. The following year, they had just one heat-related stoppage.
Basic maintenance prevents most chiller problems. Common tasks include:
- Checking refrigerant pressure every 3 months
- Cleaning condenser coils twice yearly
- Testing water quality monthly
- Replacing filters based on pressure drop readings
A Hull chemical plant spends £1,870 annually on scheduled chiller maintenance. Their previous approach of running until failure cost them an average of £7,400 yearly in emergency repairs and lost production.
Chillers typically last 12–15 years with proper care. Depending on size and type, the compressor usually needs replacement after 8–10 years at £2,500–£4,000.
