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 2021 Sheet.
Glycol Concentration 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 70 lbs/hour | SHEET CALENDERING PE 35 lbs/hour/ton ABS 60 lbs/hour/ton PS 60 lbs/hour/ton PROFILE & PIPE HDPE 50 lbs/hour/ton LDPE 50 lbs/hour/ton PP 50 lbs/hour/ton PET 50 lbs/hour/ton ABS 60 lbs/hour/ton PVC 75 lbs/hour/ton PS 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 |
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| FEED THROAT INJECTION MOLDING | |||
| 1/2 ton up to 400 ton machine. 1 ton over 400 ton machine. |
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| BLOW HOLDING | VACUUM FORMING |
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| POLYOLFINS 40 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 |
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| 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 |
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| 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 |
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| 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. |
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| MIXER: lbs/hour x .5 x temp. difference + 0.2 hp. = tons | |
| 12,000. Approx. temp. in 220° F. and temp. out 100° F. |
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| WATER PUMPS: 0.2 ton/hp. VACUUM FORMING: S.H. is specific heat of plastic. |
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| 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. |
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| 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). |
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| 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) |
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| 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. |
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| 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 |
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| STEEL QUENCHING: | |
| Continuous - lbs/hour x 0.166 x (temp. in - temp. out) = Tons. 1,2000. Batch - lbs/load x 0.166 x (temp. in - temp. out) = Tons. Quench time (hours) x 12,000. |
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| FAN BEARINGS: 0.2 ton/fan motor (2 gpm/fan motor). TRANSFORMER COOLING: 1 KVA = 1 ton. |
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