Loadsizing

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 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 MOLDINGEXTRUSION
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 HOLDINGVACUUM 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 SIZINGGENERAL 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.
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.
1,2000.
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.