6 Signs Your Facility Needs a Custom Air-Cooled Chiller

While standard air-cooled chillers work well for many industrial processes, some facilities have unique cooling requirements that demand a custom-engineered solution. A custom air-cooled chiller ensures your cooling system is perfectly matched to your process, space constraints, compliance needs, and operational environment.

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Here are six clear signs that your operation would benefit from a custom industrial air-cooled chiller.

1. Unique Process Cooling Requirements

Processes with variable cooling loads, precise temperature tolerances, or multi-stage cooling needs often require custom chillers. Standard chillers may be over- or under-sized, resulting in inefficient operation, temperature swings, or equipment stress.

Example: In plastic extrusion, the cooling load can shift dramatically between production runs, requiring dynamic load management and precise temperature control, achievable only with custom-designed controls and capacity modulation. In , Berg designed a custom air-cooled chiller for Cap-Thin Molds Inc., to meet precise cooling requirements for plastic cap and thin-wall molding.

2. Space and Installation Constraints

Limited space, unusual building layouts, or retrofit projects may call for custom chillers designed with compact footprints, remote condensers, or flexible mounting options. Custom engineering allows chillers to fit into constrained mechanical rooms, be mounted outdoors or rooftops, or incorporate remote condensers to maximize floor space.

Example: In a food processing plant, production space is often at a premium, so the chiller may need to be located outside or in a dedicated mechanical room with non-standard dimensions. In , Berg supplied a space-saving outdoor air-cooled chiller for Delmar Foods, which was designed to fit a limited footprint while delivering reliable process cooling.

3. Harsh or Unusual Operating Environments

Standard industrial chillers are typically rated for mild to moderate conditions. For facilities in coastal, high-humidity, or extreme temperature environments, chillers built with specialized materials and coatings to withstand tough conditions can ensure reliability and longevity.

Example: A chemical processing facility in a coastal region may require marine-grade coatings, corrosion-resistant materials, and climate-specific controls to ensure reliable long-term performance. In , Berg engineered a custom electronics cooling solution for Elta Systems Ltd., designed for deployment on a military vessel operating in harsh marine environments.

4. Regulatory and Industry-Specific Compliance

Industries such as pharmaceuticals, food & beverage, and energy processing must meet strict regulatory standards for temperature control, refrigerants, and operational safety. Custom chillers can be built to support compliance and audit-readiness.

Example: A pharmaceutical plant may need precise GMP-compliant temperature control, validated performance documentation, and redundant systems for critical processes. In , Berg supplied a low-temperature air-cooled chiller to BioVectra Inc., designed to meet stringent pharmaceutical process requirements and validated temperature performance.

5. Integration with Existing Process and Controls

In many industrial facilities, cooling systems are just one part of a larger, interconnected process. Custom chillers can be designed to seamlessly integrate with existing automation systems, SCADA platforms, and remote monitoring solutions.

Example: Berg provided a custom air-cooled chiller for GTUIT's modular gas treatment system, ensuring seamless integration with process controls for remote wellhead operations.

6. Energy Efficiency and Sustainability Goals

For energy-intensive industries, custom chillers can incorporate features like variable frequency drives (VFDs), heat recovery, and free cooling, helping facilities meet energy efficiency and carbon reduction goals.

Example: In a dairy processing facility, waste heat from the chiller could be repurposed to preheat water for CIP (clean-in-place) systems. In , Berg an energy-efficient outdoor air-cooled chiller for a leading dairy products corporation, helping them reduce energy use while maintaining reliable cooling.

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Additional resources:
Air-Cooled Integrated Chiller: Benefits, Types, and Optimal Applications Explained

Future-Proof Your Facility with a Custom Air-Cooled Chiller

The right custom chiller does more than solve immediate cooling challenges. It also future-proofs your operation, enhancing:

• Process uptime and reliability
• Operational efficiency
• Long-term energy savings
• Regulatory compliance

To see how Berg's custom engineering expertise supports industries from plastics and food production to natural gas processing and pharmaceuticals, explore our Project Spotlights.

Partnering with Berg for Custom Industrial Cooling Solutions

At Berg Chilling Systems, we specialize in designing and manufacturing custom-engineered air-cooled chillers for a wide range of industries, including food & beverage, plastics, pharmaceuticals, energy, and beyond. We work closely with each client to:

• Understand your specific process and cooling challenges
• Design a solution that maximizes performance, reliability, and energy efficiency
• Ensure smooth integration with your existing systems and infrastructure

What Are the Cooling Requirements for Your Facility?

Understanding your facility's cooling requirements is the first step to choosing the right chiller. Factors such as the size of your space, the heat load, and the nature of your operations all impact the specifications you need. A manufacturing facility might require high-capacity cooling to manage equipment heat, while a smaller office might need a compact solution. 

Evolution Cooling's team excels at assessing these needs, ensuring you select a chiller with the right capacity and configuration. Our tailored recommendations account for operational demands, ensuring maximum efficiency and minimal downtime. Whether you're upgrading an outdated system or installing a new one, aligning your choice with your cooling demands ensures optimal performance and long-term reliability.

What Are the Different Types of Chillers Available?

Chillers are classified into various types, each tailored to specific applications and operational needs. Air-cooled chillers are a popular choice for smaller facilities or locations where water resources are limited, as they rely on ambient air to dissipate heat. These systems are easier to install and maintain, making them suitable for buildings with space constraints or lower cooling demands. However, they can be less efficient in hot climates, where ambient temperatures challenge heat exchange. Water-cooled chillers, on the other hand, are designed for larger installations requiring high-efficiency cooling. These systems use a water source, such as a cooling tower, to manage heat more effectively, offering superior performance even in demanding environments. 

Other types include evaporative chillers, which combine air and water cooling for enhanced efficiency, and hybrid systems that adapt to fluctuating demands. Selecting the right chiller depends on factors such as facility size, energy goals, and environmental conditions. A thorough evaluation ensures a solution that balances operational needs with cost efficiency. At Evolution Cooling, we can provide guidance on the best option for your needs, offering an extensive range of models to fit any facility. 

How Does Energy Efficiency Impact Chiller Performance and Costs?

Energy efficiency is a critical consideration when purchasing a chiller. Choosing an energy-efficient model reduces operational costs and aligns with sustainability goals. Look for chillers with a high SEER (Seasonal Energy Efficiency Ratio) rating or advanced features, such as variable speed drives, to improve performance. 

Please note that Evolution Cooling prioritises efficiency, offering a selection of chillers that not only reduce energy consumption but also enhance long-term savings. Our expertise ensures that you select a chiller designed to meet your energy requirements while keeping utility bills manageable. With the right model, you can achieve both peak performance and cost-effectiveness, ensuring your investment pays off over time.

How Important Is Maintenance and Servicing for Chiller Longevity?

Routine maintenance is vital for keeping a chiller functioning efficiently and extending its lifespan. Without regular servicing, chillers are more prone to reduced performance, higher energy consumption, and unexpected breakdowns, which can be costly to repair. Proper maintenance involves inspecting key components such as compressors, condensers, and evaporators, as well as monitoring refrigerant levels and cleaning filters. Addressing minor issues early prevents them from escalating into significant problems that disrupt operations. Regular maintenance also improves energy efficiency, ensuring the system runs optimally and lowers operational costs over time.

We help to minimise these risks by providing thorough maintenance services, including routine inspections and prompt repairs. With quick access to replacement parts and expert servicing, operational downtime is kept to a minimum, enhancing both the reliability and longevity of the equipment.

What Should You Know About Initial Costs Versus Lifetime Costs?

When buying a new chiller, balancing initial costs with lifetime costs is crucial. While cheaper models may seem attractive, they often come with higher operational expenses due to inefficiency or frequent repairs. 

Our energy-efficient chillers and tailored maintenance plans reduce overall costs, making them a sound investment. By focusing on both upfront affordability and ongoing savings, we will ensure that your chosen system provides maximum return on investment over its operational life. This factor alone makes us the ideal choice for businesses prioritising cost-effectiveness and reliability.

Factors When Buying a New Chiller Unit in Summary

Choosing a new chiller involves balancing technical and practical requirements. By thoroughly assessing your facility's needs and the options available, you can ensure optimal performance and cost-effectiveness. With expert guidance and comprehensive solutions, Evolution Cooling makes it easier to find the perfect chiller unit tailored to your goals.

Want more information on Air-Cooled Integrated Chiller? Feel free to contact us.