EXTRUTEX Air Chiller – Industrial Water Cooling System

The EXTRUTEX Air Chiller is an industrial refrigeration and water-cooling system designed for reliable temperature control in plastics processing, extrusion, injection molding, compounding, industrial manufacturing and other applications where stable process-water temperature is essential.

Designed in Austria by EXTRUTEX engineering specialists and manufactured in China at our production facilities in Nanjing and Shanghai, the EXTRUTEX Air Chiller combines European engineering principles with efficient industrial manufacturing. The result is a practical cooling system designed for continuous industrial operation, straightforward maintenance and dependable temperature control.

EXTRUTEX air-cooled chillers are available in a wide range of capacities, from compact 10 kW refrigeration systems to large industrial units with up to 180 kW refrigeration capacity. Different configurations can be selected according to production requirements, cooling-water flow, installation conditions and required process temperature.

The standard system is designed to cool water from approximately 12°C inlet temperature to 7°C outlet temperature under a 35°C ambient temperature. The operating temperature range of the chilled-water system is approximately 7–35°C, while lower cooling temperatures can be engineered according to customer requirements and application conditions.

Industrial Applications

Stable cooling is an important part of modern plastics processing. During extrusion, injection molding and other polymer-processing operations, uncontrolled process temperatures can affect dimensional accuracy, surface quality, production stability and cycle time. The EXTRUTEX Air Chiller provides a controlled source of chilled water for industrial cooling circuits.

The system can be used for a wide range of applications, including:

• PVC pipe extrusion lines
• PE and PP pipe extrusion lines
• UPVC profile extrusion
• WPC profile and board production
• Plastic sheet extrusion
• Plastic film processing
• Injection molding machines
• Compounding and masterbatch production
• Plastic recycling systems
• Extruder barrel and process cooling
• Vacuum calibration tank cooling
• Industrial process-water cooling
• General manufacturing equipment requiring chilled water

The chilled-water supply can be integrated into an individual machine or connected to a centralized factory cooling circuit. EXTRUTEX can also engineer the cooling system according to the required flow rate, temperature, installation space and production environment.

Performance Characteristics

Stable Cooling Temperature

The standard EXTRUTEX Air Chiller is designed for chilled-water temperatures from approximately 7°C to 35°C. The standard operating condition is based on chilled-water entering the system at 12°C and leaving at 7°C, with an ambient air temperature of 35°C.

For applications requiring lower temperatures, EXTRUTEX can develop customized configurations according to the required process conditions. Special applications should be evaluated according to refrigerant selection, evaporator configuration, ambient temperature, water quality and required cooling capacity.

Microcomputer Temperature Control

An intelligent microcomputer control system monitors and manages the chiller operating conditions. The controller provides temperature monitoring and automatic system operation, helping maintain consistent chilled-water conditions during production. Temperature control accuracy is designed around approximately ±1°C, depending on operating conditions and system configuration.

Compressor and Pump Protection

The compressor and water pump are equipped with overload protection. These protective functions help prevent damage caused by abnormal operating conditions and contribute to longer service life of the major components.

Protection is particularly important for industrial equipment operating continuously in extrusion and manufacturing environments, where unexpected shutdowns can interrupt production and increase operating costs.

Multiple Safety Protection Systems

The EXTRUTEX Air Chiller incorporates multiple protective functions designed to monitor the refrigeration and water circuits. Depending on model configuration, protection includes high-pressure protection, low-pressure protection, compressor overload protection, pump overload protection, antifreeze protection and water-flow protection.

These functions work together to protect the refrigeration circuit and help maintain safe operation under changing production conditions.

Industrial Construction

Stainless Steel Water Tank

The water tank is manufactured from stainless steel and incorporates thermal insulation. Stainless steel construction provides a durable solution for industrial chilled-water applications, while the insulation layer helps reduce unnecessary heat transfer between the chilled water and the surrounding environment.

Insulated Refrigeration and Water Lines

The relevant chilled-water and refrigeration piping is insulated to improve cooling efficiency and reduce unwanted heat gain. Proper insulation is particularly important when chilled-water equipment is installed in warm industrial environments.

Low-Speed Axial Fan

The air-cooled condenser uses axial-flow fans designed for efficient heat dissipation. The low-speed fan configuration helps reduce operating noise while providing the airflow required by the condenser.

Energy-Conscious Fan Control

The fan operation is coordinated with the compressor. When the compressor stops, the fan can stop after a controlled delay. This arrangement reduces unnecessary fan operation and can contribute to lower electrical energy consumption.

Working Principle

The EXTRUTEX Air Chiller operates through a conventional mechanical refrigeration cycle. Heat is removed from the process water and rejected to the surrounding air through the air-cooled condenser.

1. Compressor: The compressor circulates the refrigerant through the refrigeration system and raises the refrigerant pressure and temperature.
2. Condenser: The hot refrigerant releases heat to the surrounding air through the finned condenser.
3. Drier Filter: The filter-drier helps remove moisture and contaminants from the refrigeration circuit.
4. Expansion Valve: The expansion valve reduces refrigerant pressure before the refrigerant enters the evaporator.
5. Evaporator: Heat is transferred from the chilled water to the refrigerant inside the evaporator, reducing the water temperature.
6. Water Pump: The pump circulates chilled water between the chiller and the industrial process.
7. Temperature Sensor: The sensor monitors water temperature and sends operating information to the control system.
8. Protection Devices: Pressure, flow and antifreeze protection systems monitor critical operating conditions.

This continuous cycle allows the chiller to remove process heat and maintain a stable chilled-water supply for connected production equipment.

Evaporator Configuration

Depending on the model and cooling capacity, the EXTRUTEX Air Chiller can use different evaporator configurations. Compact models may utilize a serpentine-pipe evaporator, while larger industrial configurations can utilize shell-type evaporators.

The evaporator is a critical component because it provides the heat-transfer interface between the chilled water and the refrigeration circuit. Its configuration is selected according to cooling capacity, water flow, operating temperature and application requirements.

Refrigeration System

The standard system specification is based on R22 refrigerant according to the supplied original specification. Refrigerant requirements and system configuration may vary according to the final production version, applicable regulations, installation country and customer requirements.

For new projects, EXTRUTEX can evaluate the appropriate refrigerant and refrigeration configuration according to the destination market and applicable environmental and safety regulations.

Technical Specifications

* The supplied original specification lists R22. Refrigerant selection for new equipment should be confirmed according to the final machine configuration and regulations applicable in the destination country.

Cooling Water Connections

The chilled-water inlet and outlet connections are selected according to the model and required water flow. Larger chillers use larger connections to accommodate the increased water circulation required by higher refrigeration capacities.

* Final connection dimensions should be confirmed according to the selected machine model and final engineering configuration.

Safety and Protection

Industrial chillers must operate reliably under continuously changing thermal loads. EXTRUTEX therefore incorporates several protection functions into the cooling system. These functions are designed to protect the refrigeration system, pump and water circuit.

• High-pressure protection
• Low-pressure protection
• Compressor overload protection
• Water pump overload protection
• Antifreeze protection
• Water-flow protection
• Temperature monitoring
• Automatic system control

Protection settings and control functions can vary according to the selected model, refrigeration circuit and customer requirements.

Intelligent Control System

The EXTRUTEX control system continuously monitors the operating temperature and controls the refrigeration equipment according to the cooling demand. The microcomputer controller provides a simple interface for monitoring system conditions and maintaining the selected water temperature.

Automatic control also reduces the need for constant manual intervention. This is useful for extrusion factories where the chiller may operate for long production shifts and must maintain stable process-water conditions.

Energy-Efficient Air Cooling

Because the condenser rejects heat directly to the surrounding air, the EXTRUTEX Air Chiller does not require a separate cooling tower for the standard air-cooled configuration. This can simplify installation and reduce the infrastructure required around the cooling system.

The low-speed axial fans are designed to provide the required condenser airflow while helping control operating noise. Fan operation is coordinated with the refrigeration cycle, including delayed stopping after compressor operation, helping prevent unnecessary fan energy consumption.

Actual energy consumption depends on refrigeration capacity, ambient temperature, water temperature, process load, operating hours and installation conditions.

EXTRUTEX Austrian Design – Manufacturing in China

EXTRUTEX develops industrial plastics-processing and auxiliary equipment based on European engineering principles. The Air Chiller series follows the same approach: practical mechanical design, straightforward operation, serviceability and reliable industrial construction.

The equipment is designed in Austria by EXTRUTEX and manufactured in China through our production facilities in Nanjing and Shanghai. This manufacturing structure allows EXTRUTEX to combine engineering development, component sourcing and industrial production while maintaining competitive equipment costs for international customers.

The chiller can be supplied as part of a complete plastics-processing project or as an independent auxiliary cooling system. EXTRUTEX can also coordinate the chiller with extrusion lines, downstream equipment, vacuum tanks, calibration systems, injection molding equipment and other process machinery.

Customized Cooling Solutions

Every factory has different cooling requirements. Water temperature, flow rate, ambient temperature, production capacity, available installation space and operating conditions can all influence the required chiller configuration.

EXTRUTEX can therefore evaluate customized cooling solutions for customers requiring different water temperatures, cooling capacities, pump configurations, water connections, control systems or installation arrangements.

For large extrusion plants, multiple chillers can also be considered as part of a centralized cooling strategy. The final configuration should be selected based on the actual heat load and required process-water flow rather than refrigeration capacity alone.

Why Choose an EXTRUTEX Air Chiller?

• European engineering: Austrian design approach for industrial applications.
• Manufacturing in China: Produced through EXTRUTEX facilities in Nanjing and Shanghai.
• Wide capacity range: Models from 10 kW to 180 kW refrigeration capacity.
• Stable temperature control: Designed for controlled chilled-water operation.
• Industrial protection: Multiple pressure, overload, flow and antifreeze protections.
• Stainless steel water tank: Durable construction with thermal insulation.
• Air-cooled condenser: No cooling tower required for the standard configuration.
• Low-noise fan system: Low-speed axial fans for efficient condenser cooling.
• Flexible applications: Suitable for extrusion, injection molding and industrial process cooling.
• Custom engineering: Cooling capacity and configuration can be adapted to project requirements.

Installation and Operation

The Air Chiller should be installed in a location with sufficient ventilation and free airflow around the air-cooled condenser. Adequate clearance should be provided to allow the condenser fan to discharge hot air efficiently and to provide convenient access for maintenance.

The chilled-water circuit should be correctly sized according to the required flow rate. Water quality, piping insulation and hydraulic resistance should also be considered during installation. Correct installation helps the chiller achieve its specified cooling performance and supports long-term operating stability.

Before commissioning, the electrical supply, water circuit, pump operation, flow protection, temperature settings and refrigeration system should be checked by qualified personnel.

Rated Performance Conditions

The published refrigeration capacities are based on the following reference operating conditions:

• Cooling-water inlet temperature: 12°C
• Cooling-water outlet temperature: 7°C
• Temperature difference: 5°C
• Ambient air inlet temperature: 35°C
• Power supply: 3-phase, 380 V, 50/60 Hz

Actual performance can vary according to ambient conditions, water flow, water temperature, refrigerant configuration, installation conditions and production load. Technical specifications should therefore be confirmed with EXTRUTEX before ordering.

Frequently Asked Questions

What is an EXTRUTEX Air Chiller used for?

It is used to produce chilled water for industrial process cooling. Typical applications include plastic extrusion, injection molding, compounding, recycling and other manufacturing processes requiring controlled water temperature.

What cooling capacity is available?

The supplied SL-A series specification covers refrigeration capacities from 10 kW to 180 kW.

What is the standard chilled-water temperature?

The reference performance condition is 12°C water entering the chiller and 7°C water leaving the chiller, with an ambient temperature of 35°C.

Can EXTRUTEX provide lower temperatures?

Yes. Lower cooling temperatures can be considered as a customized engineering option, subject to the required application conditions and final refrigeration configuration.

Where are EXTRUTEX chillers manufactured?

The Air Chiller is designed in Austria by EXTRUTEX and manufactured in China through production facilities in Nanjing and Shanghai.

Can the chiller be integrated with an extrusion line?

Yes. The chiller can be integrated with plastics extrusion lines and other process equipment requiring controlled cooling water. The required capacity should be calculated according to the thermal load and water circulation requirements of the complete system.

EXTRUTEX Air Chiller for Industrial Process Cooling

The EXTRUTEX Air Chiller provides a practical solution for factories requiring reliable chilled-water production without the complexity of a separate cooling tower system. With Austrian engineering design, manufacturing in China, multiple refrigeration capacities, automatic temperature control and integrated protection functions, the system can be configured for a broad range of industrial cooling applications.

From a compact 10 kW unit for smaller equipment to a 180 kW industrial model, the EXTRUTEX SL-A series provides scalable cooling capacity for modern plastics-processing facilities. The combination of stainless steel water-tank construction, insulated cooling circuits, protected compressor and pump operation, air-cooled condensation and automatic control provides a dependable foundation for continuous industrial operation.

For extrusion plants, injection molding factories, compounding facilities and other polymer-processing applications, EXTRUTEX can evaluate the required refrigeration capacity and develop the appropriate cooling configuration according to the production process.

EXTRUTEX – Austrian Design. Chinese Manufacturing. Industrial Cooling Technology for Global Plastics Processing.

Technical note: Specifications may be modified according to engineering improvements, component availability, destination-market requirements and customer customization. Final technical parameters, dimensions, refrigerant selection, electrical configuration and performance should be confirmed with EXTRUTEX before purchase.