Load Sizing Chillers

To size your production machine cooling load use the following information: Calculate the total lbs/hour of material your machine uses and divide it by the lbs/ton listed below for your specific process. This will give you the tons of cooling required at 50° F leaving water temperature.

Download the Load Sizing Formulas Sheet.

Glycol Requirements - concentrations required to operate at different leaving water temperatures to prevent freezing.

When operating below 50 F you must decrease the rated chiller cooling capacity by 2% for every one degree F you operate below 50° F.

To correct for 45° F operation you would divide the chiller rated cooling load by 0.9. See calculation: 100% - (2% x 5° F below 50° F) = 90% or 0.9.

You can also fill out our Sizing Data Sheet and fax it to us at (905) 513 - 8358. Click here and then select File/Print (there are four pages).

CHILLER SIZING FORMULAS
INJECTION MOLDING EXTRUSION
HDPE
LDPE
PP
ACRYLIC
PPO
NYLON
DERLIN
UREATHANE
PET
PS
ABS
PC
ACETAL
CELCON
PVC
30 lbs/hour
35 lbs/hour
35 lbs/hour
35 lbs/hour
40 lbs/hour
40 lbs/hour
40 lbs/hour
40 lbs/hour
40 lbs/hour
50 lbs/hour
50 lbs/hour
50 lbs/hour
50 lbs/hour
50 lbs/hour
60 lbs/hour

SHEET CALENDERING

PE 35 lbs/hour/ton
ABS 60 lbs/hour/ton
PS 60 lbs/hour/ton

PROFILE & PIPE

HDPE 50 - 60 lbs/hour/ton
LDPE 50 - 60 lbs/hour/ton
PP 50 - 60 lbs/hour/ton
PET 50 - 60 lbs/hour/ton
ABS 60 - 75 lbs/hour/ton
PVC 60 - 75 lbs/hour/ton

EXTRUDER COOLING

Barrel 1 ton/" screw dia.
Screw 2 tons
Throat 1/2 ton up to 3"
Throat 1 ton 4" to 6"
Gear Box (oil) 100 hp / ton

FEED THROAT INJECTION MOLDING
1/2 ton up to 400 ton machine.
1 ton over 400 ton machine.
BLOW HOLDING VACUUM FORMING
POLYOLFINS 35 lbs/hour/ton
PET 40 lbs/hour/ton
PVC 70 lbs/hour/ton
HDPE 70 lbs/hour/ton
LDPE 70 lbs/hour/ton
PP 70 lbs/hour/ton
PS 200 lbs/hour/ton
PVC 250 lbs/hour/ton
COOLING TOWER SIZING GENERAL FORMULAE
Hyd. Cooling .11 hp / ton
Vacuum Pump .1 hp / ton
Rubber Mills .1 hp / ton
Gear Drives .1 hp / ton
Water Pumps .2 hp / ton
Air Comp. intern. .16 hp / ton
Air Comp. after. .2 hp / ton
Spot Welders 100 kw / ton
Chiller Condenser 1 ton = 1 ton
Hot Runner Molds kw x 3414 x .5
Chiller Ton 12,000 btu
Chiller Flow 2.4 gpm / ton
Chiller Tons gpm x TD div. 24
Chiller With Water Range 42 F to 70 F
Chiller With Glycol Range 15 F to 42 F
Tower Ton 15,000 btu
Tower Flow 3 gpm / /ton
Tower Tons gpm x TD div. 30
To run any of the above equipment on a chiller multiply the tower cooling load by 1.25. TD - Temperature Difference (between water in & out)
BLOWN FILM LOAD SIZING  
100 CFM
100 CFM
100 CFM

Entering Air Condition

40 F (4.4 C) Air Off 1.14 tons Ent. Glycol 33 F
45 F (7.2 C) Air Off 1.05 tons Ent. Glycol 35 F
50 F (10 C) Air Off 0.85 tons Ent. Water 40 F

90 F dry bulb / 78 F wet bulb
Includes blower motor heat
DIE CFM 3 cfm / lb.
(guide only) 150 to 170 cfm / die inch
 
HOT RUNNER MOLDS convert heater watts to btu's and divide by 2. (watts x 3.414 divide by 24,000 Btu's)
Chilled water flow rate is 2.4 gpm/ton.
Chiller ton is 12,000 Btu's
Chiller operating temperature range with water is from 45° F. to 60° F. leaving water temperature.
Chiller operating temperature range with glycol/water is from 25° F. to 45° F. leaving water temperature.
MIXER: lbs/hour x .5 x temp. difference + 0.2 hp. = tons
12,000
Approx. temp. in 220° F. and temp. out 100° F.

WATER PUMPS: 0.2 ton/hp.

VACUUM FORMING: S.H. is specific heat of plastic.
Tons = (temp. sheet on - temp. sheet off) x S.H> x lbs/hour
12,000 Btu's/ton
* Sheet is cooled by the surrounding air, lbs/hour may be increased by 15%
COOLING & HEATING LOAD: S.H. is specific heat of material.

BTU's = lbs/hour x (temp. start - temp.end) x S.H.

MOLD HEAT UP TIME:
S.H. is specific heat of mold material.

Time = weight (lbs) x (temp. start - temp. end) x S.H.
heater capacity (Btu's)
FOR TOWER WATER
SPOT WELDERS: 1/4 ton/tip (chilled water)

MOLD ROOM COOLING:
80 sq. ft./ton (16' ceiling)

TRANSFORMER COOLING:
1 KVA = 1 ton

FAN BEARINGS:
0.2 ton/fan motor (2 gpm/fan motor)
Hydraulic cooling: 10 hp = 1 ton
Vacuum pumps: 10 hp = 1 ton
Chiller condenser: 1 ton chiller = 1 ton cooling tower.
Air compressors: 10 hp = 1 ton (internal oil cooling).
10 hp = 1 ton (after cooler cooling).
Tower water flow rate is 3 gpm/ton.
Tower ton is 15,000 Btu'sTower leaving water temperature depends on local wet bulb temperatures, normal range is from 75° F. to 85° F. in the summer months and as low as 50° F. in winter months.
PLATING BATHS: DC amps x DC volts x 3.414 x 75% eff. = Tons
12,000 btu/s
DIE CASTING: Zinc - lbs/hour x 35 btu/lb = Tons (pour at 800 F. Remove at 600 F.)
12,000 b
Aluminum - lbs/hour x 325 btu/lb = Tons (pour at 1200 F. Remove at 600 F.)
12,000 Btu's
STEEL QUENCHING:
Continuous - lbs/hour x 0.166 x (temp. in - temp. out) = Tons
12,000
Batch - lbs/load x 0.166 x (temp. in - temp. out) = Tons
Quench time (hours) x 12,000
FAN BEARINGS: 0.2 ton/fan motor (2 gpm/fan motor)

TRANSFORMER COOLING: 1 KVA = 1 ton

What is a chiller? To learn more about industrial chillers click here. For more information on each product line click on the images below:

In the interest of continuous improvement, Temperature Corporation reserves the right to change specifications without notice. While every effort is made to ensure accuracy, Temperature Corporation accepts no responsibility or liability resulting from the use of this information. Jan to Dec 2016

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Temperature Corporation, 111 Esna Park Drive, Unit 7, Markham, Ontario, L3R 1H2
Toll Free: 1.877.513.8310 ~ Email: