Closed-Loop Precision Temperature Control & Continuous Duty
Industrial Air-Cooled Chillers for Plastic Recycling & Extrusion
High-efficiency packaged air-cooled water chillers engineered for continuous 24/7 thermal management across plastic pelletizing lines, extrusion systems, PVC pulverizers, and hydraulic power units. Featuring premium hermetic scroll compressors, intelligent microcomputer temperature stability (±0.5°C), integrated stainless steel water tanks, and environmentally compliant refrigerants without requiring external cooling towers.
Engineered for Harsh Industrial Recycling Environments
Reliable process cooling protects extruder dies, prevents plastic pellet agglomeration, and stabilizes hydraulic oil under 24/7 production demands.
Hermetic Scroll Compressors & Dual Circuits
Utilizes globally recognized hermetic scroll or rotor compressors delivering ultra-high energy efficiency (EER > 3.2), low vibration, and quiet operation. Higher-capacity models feature independent dual or quad refrigeration circuits, allowing automated staging and full redundancy so maintenance never halts your extrusion line.
Zero-Downtime RedundancyMicrocomputer Precision (±0.5°C)
Smart digital PID control panel provides real-time dual temperature monitoring (inlet/outlet) between 5°C and 35°C with automated diagnostic fault codes and RS485 communication for PLC integration.
Tower-Free Air-Cooled Condensers
High-efficiency microchannel (MCHE) or inner-grooved copper finned condensers coupled with low-RPM axial fans reject heat directly to ambient air, completely eliminating cooling towers, water scaling, and Legionella risks.
Built-in SUS304 Tank & Pump
Factory-integrated open stainless steel insulated reservoir (25L to 450L) with immersion coil evaporator and high-head multistage stainless circulating pump for immediate plug-and-play installation.
8-Point Comprehensive Protection
Equipped with compressor internal overheat cutoff, high/low refrigerant pressure switches, 3-phase reverse phase protector, freeze prevention thermostat, and water flow level safety interlocks.
Dust-Proof Enclosure for Plastic Recycling Plants
Unlike standard commercial chillers, Energycle industrial chillers are built inside heavy-gauge electro-galvanized steel cabinets with polyester powder coating. Washable quick-release air intake pre-filters prevent airborne plastic fluff, shredded dust, and fines from fouling condenser fins, ensuring sustained cooling efficiency even in dirty recycling workshop environments.
Critical Process Cooling Applications
How precision chilled water safeguards equipment performance, enhances pellet morphology, and maintains continuous throughput across plastics recycling operations.
Water-Ring & Strand Pelletizing
Delivers continuous 10°C–15°C chilled water directly to cutting water jackets and cooling flumes. Rapidly quenches molten polymer exiting extruder die heads, preventing pellet deformation, hollow centers, and cutting blade clumping.
Pelletizing QualityExtruder Throat & Barrel Zones
Provides intensive cooling at the extruder feed throat section, preventing regrind and film fluff from prematurely softening and bridging at the hopper throat, ensuring uninterrupted infeed flow.
Feed Throat CoolingPVC Micronizers & Pulverizers
Absorbs friction heat from high-speed rotating grinding discs inside PVC pulverizer chambers, preventing PVC powder from melting, decomposing, or clogging the discharge mill.
Thermal ProtectionHydraulic Power Unit Cooling for Heavy Recycling Machinery
Maintains hydraulic oil temperature below 50°C on heavy-duty hydraulic balers, debalers, and guillotine cutters operating around the clock. Prevents hydraulic fluid viscosity breakdown, preserves valve seal elasticity, and eliminates pump cavitation.
Oil Circuit StabilityClosed-Loop Refrigeration Cycle
How Energycle packaged air-cooled chillers continuously maintain stable process temperatures without water loss or environmental contamination.
Heat Absorption
Warm process fluid (15°C–25°C) from pelletizer water baths or extruder throats returns to the built-in SUS304 insulated reservoir.
Refrigerant Evaporation
High-efficiency submerged evaporator coils extract heat rapidly into the R410A/R407C closed refrigerant circuit.
Ambient Heat Rejection
High-volume axial fans draw ambient air through microchannel condenser coils, rejecting thermal energy cleanly outdoors.
Precision Chilled Delivery
Integrated stainless steel booster pump recirculates clean, temperature-regulated chilled water (5°C–12°C) back to machinery.
Technical Specifications & Model Selection
Standard parameters for Energycle packaged industrial air-cooled chillers. Custom voltages (220V/380V/440V/480V 50/60Hz), dual pump systems, and explosion-proof designs available upon request.
| Model / Parameter | Unit | EC-AC03 | EC-AC05 | EC-AC10 | EC-AC15 | EC-AC20 | EC-AC30 | EC-AC40 | EC-AC50 |
|---|---|---|---|---|---|---|---|---|---|
| Nominal Cooling Capacity | kW (kcal/h) | 8.5 (7,310) | 14.2 (12,210) | 28.5 (24,510) | 45.0 (38,700) | 57.6 (49,530) | 85.0 (73,100) | 109.6 (94,250) | 180.0 (154,800) |
| Compressor Power | HP (kW) | 3 HP (2.2) | 5 HP (3.75) | 10 HP (7.5) | 15 HP (11.2) | 20 HP (15.0) | 30 HP (22.5) | 40 HP (30.0) | 60 HP (45.0) |
| Compressor Type & Qty | – | Hermetic Scroll (1 Circuit) | Dual/Quad Hermetic Scroll (Independent Circuits) | ||||||
| Total Input Power | kW | 3.4 | 5.1 | 9.85 | 15.4 | 20.4 | 30.6 | 40.4 | 59.2 |
| Refrigerant Type | – | Eco-friendly R410A / R407C (R22 optional upon request) | |||||||
| Condenser Airflow | m³/h | 3,000 | 5,000 | 10,000 | 15,000 | 20,000 | 30,000 | 40,000 | 60,000 |
| Chilled Water Flow | m³/h | 1.5 | 2.5 | 4.9 | 7.8 | 9.9 | 14.6 | 18.8 | 31.0 |
| Water Tank Capacity | L | 40 | 60 | 100 | 150 | 200 | 300 | 380 | 450 |
| Water Pipe Connection | Inch | 1" | 1" | 1-1/2" | 2" | 2" | 2-1/2" | 2-1/2" | 3" |
| Operating Weight | kg | 150 | 170 | 370 | 520 | 790 | 880 | 1,100 | 1,420 |
* Nominal cooling capacity measured at chilled water inlet/outlet 15°C / 10°C, ambient temperature 35°C. Performance can be optimized for low-temperature brine/glycol solutions down to -5°C.
Air-Cooled Packaged Chiller vs Cooling Tower & Open Basin Systems
Selecting the right process cooling architecture balances water consumption, installation complexity, temperature stability, and winter freeze vulnerability.
| Evaluation Criteria | Energycle Air-Cooled Packaged Chiller | Water-Cooled Chiller + Cooling Tower | Direct Open Basin / Raw Well Cooling |
|---|---|---|---|
| System Architecture | Factory-packaged closed loop; built-in stainless buffer tank and circulating pump | Central chiller requiring external cooling tower, condenser pumps, and dual piping | Open evaporative pond or raw groundwater pumped directly through heat exchangers |
| Water Consumption & Treatment | Zero water consumption; closed glycol circuit prevents scaling and biological fouling | High evaporative water loss; requires continuous biocides and bleed-off chemical control | Massive fresh water usage; severe mineral scaling and pipeline silt accumulation |
| Installation & Plant Footprint | Compact outdoor or rooftop skid installation; connect process fluid supply and return | Large mechanical room footprint plus elevated outdoor cooling tower structure | Extensive ground footprint for settling ponds, retention pits, and pump housings |
| Temperature Stability & Precision | Microprocessor PID control maintaining setpoint within ±0.5°C to ±1.0°C | Stable primary chilling, but condenser cooling capacity varies with wet-bulb humidity | Wide temperature drift influenced by ambient seasonal weather and groundwater shifts |
| Winter Freeze Protection | Automated anti-freeze control routines, glycol compatibility, and fan speed modulation | Vulnerable to tower basin freeze-up; requires basin heaters and dry-cooling bypass valves | Severe freezing risk in cold climates; complex seasonal drainage and winterization |
Reliable Support Throughout the Equipment Lifecycle
From installation planning to routine maintenance, our service team helps keep your equipment operating safely, consistently, and efficiently.
1-Year Limited Warranty
Coverage includes manufacturing defects in major mechanical and electrical components for one year. Normal wear parts and damage caused by improper operation are handled separately.
Installation Guidance
We provide layout, foundation, utility, clearance, line-integration, and commissioning guidance to support a smooth installation and reliable startup.
Spare Parts Supply
Replacement wear parts, bearings, seals, sensors, electrical components, and other service items are available for scheduled maintenance and long-term operation.
Technical Assistance
Remote troubleshooting, operating recommendations, maintenance guidance, and optional on-site service are available when your project needs additional support.
Frequently Asked Questions
Practical engineering answers regarding chiller selection, thermal sizing, and integration with plastic recycling lines.
Plastic recycling lines involve intense heat generation across multiple stages. In pelletizing systems, molten polymer exiting the die head must be rapidly solidified in water ring pelletizers or cooling baths to achieve consistent pellet geometry and prevent clumping. Furthermore, extruder feed throat cooling prevents premature polymer melting and bridging in the hopper, while PVC pulverizers require continuous chamber cooling to prevent thermal degradation.
Air-cooled chillers reject heat directly to ambient air using built-in high-volume axial fans. They eliminate the need for external cooling towers, water treatment chemicals, tower circulation pumps, and makeup water supplies. This dramatically reduces installation footprint, avoids mineral scaling in hard water areas, and makes them ideal for recycling plants with restricted water availability or cold winter climates where outdoor cooling towers are prone to freezing.
Chiller sizing depends on the total thermal heat load of your line: Q = m × Cp × ΔT, where m is the polymer output throughput per hour (kg/h), Cp is the specific heat capacity of the plastic (e.g., PP, PE, PET, or PVC), and ΔT is the temperature reduction from melt to solid state, plus additional cooling requirements for extruder feed throats and hydraulic power units. Energycle application engineers can calculate your exact BTU/hr or kW load based on your line setup.
Yes. When cooling setpoints below 5°C are required—or in cold geographical regions where outdoor ambient temperatures drop below freezing—the system can be charged with an ethylene or propylene glycol water solution (typically 20%–35% concentration). This prevents evaporator freezing and allows stable operation down to -5°C to -10°C fluid delivery.
Energycle packaged chillers include an 8-point automated protection matrix: compressor internal thermal overload protection, high and low refrigerant pressure cutout switches, reverse-phase and phase-loss electrical monitoring, anti-freeze thermostat safety, water flow switch cutoff, water level sensors in the reservoir, and an emergency stop circuit. All alarms display distinct error codes on the microcomputer controller for swift troubleshooting.
Configure Your Process Cooling System
Tell us your plant throughput, polymer type (PET, PP, PE, PVC), and heat points (pelletizer water bath, extruder feed throat, hydraulic power unit). Our thermal engineers will calculate the required kW cooling capacity and provide a custom quotation.