There are three different types of the cooling system in plastic injection moulding: water cooling, air cooling, and mechanical cooling. Water-cooling is used for high-temperature materials and it’s also the most common system in use today. Air-cooling is used when a product needs to be cooled quickly or when there isn’t enough space for water to circulate properly. Mechanical cooling is a more expensive option but it’s also one of the most efficient ways to cool down plastic products.
They are mainly used in industries like manufacturing and chemical processing.
An air cooled water chiller works by using an evaporative cooling system. It uses a refrigerant to absorb heat from the water and then release it into the atmosphere.
The heat transfer process is done through condensation.
Air-cooled water chillers are mainly used in industries like manufacturing and chemical processing because they can remove high amounts of heat at a low cost of energy input.
Advantages and Disadvantages of Air-Cooled Water Chiller
An air-cooled water chiller is a device that cools water by taking advantage of the ambient air.
It is also known as a mold cooler, because it is often used in the process of cooling molds for metal casting.
Air-cooled water chillers are typically used when there is not enough space for a water-cooled chiller, or when the ambient environment does not allow for the use of a water-cooled chiller.
Advantages: Air cooled chillers are usually cheaper to purchase and install than water cooled chillers. They also have fewer moving parts, which makes them easier to maintain and service.
Air cooled chillers are also more energy efficient than their counterparts.
An Introduction to Water-Cooled Air Cycle Chiller Systems
A water-cooled air cycle chiller is a type of heat pump that has been used for many years.
It is an energy-efficient system that can be used in hot and dry climates.
The system is made up of a compressor, condenser, evaporator, and refrigerant loop.
The compressor takes the refrigerant and moves it to the condenser, where it is cooled by water to release heat into the atmosphere.
The refrigerant then goes to the evaporator where it absorbs heat from the air, which causes it to change from liquid to gas.
The gas then travels back through the loop and finally back into the compressor.
What is an Injection Molding Machine?
Injection molding is a manufacturing process for shaping plastics and other materials.
In this process, liquid material is forced into a mold cavity which creates the desired shape.
The machine that does this is called the injection molding machine and it has two main parts: the injection unit and the clamping unit.
The injection unit injects the plastic material into the mold cavity at high pressure while the clamping unit compresses or clamps down on it to ensure that it takes on a uniform thickness throughout.
How does an Injection Molding Process work?
Injection molding is a manufacturing process for producing parts from plastic, metal and other materials. The process involves injection of material into a mold that has been heated to the melting point of the material. The mold closes around the molten material and cools it into the desired shape.
The process can be used to produce large numbers of identical products (such as parts in an assembly line) or small batches where each product meets customer specifications.
What are the Different Types of Chillers Used in a Plastic Injection Molding Process?
Chillers are the most important part of injection molding machines.
They are used for cooling the plastic material before it enters the mold and for cooling the molten plastic after it leaves the mold.
There are two types of chillers: air-cooled and water-cooled. Air-cooled chillers cools down plastics by blowing cold air on them, while water-cooled chillers cools down plastics by spraying water on them.
Why Choose Geson Injection Molding Chiller?
If you are finding industrial injection molding and blow molding chillers for your plastic process cooling system.
Geson water cooled chiller for injection molding machine can meet all your varied of requirements.
Here, you will have the ultimate economical injection mold chiller solution.
From the professionally experienced R&D team, you will satisfy the industrial water cooled chiller system.
We can supply the following types of industrial water chiller:
You can get the following services: Customize chiller types, compressor types. Precious proper cooling temperature. The most suitable economical refrigerant. The OEM brand for your brand. Stable operation with 40000 hours failure-free. Customize the voltage as your need.
Contact our engineer, to get the right solution for your plastics industry injection molding applications.
Plastic extrusion manufacturing is that the melted thermoplastic material is fed through a hole.
Creates a continuous length of uniform section of the part.
Two different types of plastic can be extruded.
Film blowing extrusion, compressed air passes through holes to create air bubbles with plastic and form plastic film.
The process of plastic extrusion requires the use of chillers, because the temperature of plastic needs to be controlled at all times during production.
Chillers are used to cool down the temperature of hot molten plastic in order for it to become solid and flowable.
If the temperature is too high, then there will be problems with adhesion and other defects in the final product.
Chiller for Injection Molding Machine
Melted plastic (jetting) enters the mold through a nozzle.
Thermoplastics are generally used, and thermosetting plastics are used individually
Metal parts can be inserted
Producing simple and complex parts
The cooling process of plastic injection molding machine is a key factor in the success of products. Without proper cooling, the product can be deformed and has reduced mechanical strength. The cooling process is also important because it helps maintain the dimensional accuracy of the product.
An effective way to cool down the heated plastic is by using a chiller for injection molding machine. It has many advantages such as:
– Reducing heat load on downstream equipment
– Improving mold filling and ejection
– Reducing cycle time
Chillers for Blow Molding Application
The melted plastic is called a blow-molded parison before it is formed.
Compressed air forces the plastic to coat the mold cavity
Use usually thermoplastic.
Injection Blow Molding – Blow-molded parisons are cast into a mold and then blown into shape.
Production of bottles with smaller openings and hollow-shaped objects
The use of chillers in the blow molding process is essential for the quality of the finished product. The blow molding process requires a plastic that can be heated to its melting point and then cooled quickly. This cooling has to happen fast enough so that the plastic does not have time to cool too much before it is injected into a mold.
Blow molding is an industrial process by which hollow, semi-solid objects are formed in a shape, typically by extrusion or injection, and then cooled. Blow molded products are very common in everyday life, such as food containers, bottles, toys and cups.
Chillers for Compression Molding Application
Forming a plastic mixture under hot pressing.
Plastic is pressed into the mold.
Before pressing, it is formed into a certain shape by preheating.
Thermoset plastic is usually used.
Sundries, Parts, Durable Rigid Thermoset PlasticsChillers are used in plastic compression molding for cooling and solidifying the plastic. They can be used for both continuous and batch production.
The following are some of the most common types of chillers:
– Air-cooled chillers
– Water-cooled chillers
– Oil-cooled chillers
– Gas coolers
Chillers for Transfer Molding Application
Preheated shaped items are placed in the transfer chamber.
The plunger turns the plastic into a liquid that flows into the mold cavity.
Usually use thermoset plastic.
The major use of chillers is for cooling liquids in the plastic transfer molding process. The chiller removes heat from the liquid and transfers it to a cooling surface. The cooled liquid then cools the plastic parts being transferred into the mold cavity.
Chillers for Rotational Molding Application
Plastic melts in bidirectionally rotating mould.
Plastic coating on the inner surface of the mold.
The rotating mold is cooled.
Production of hollow parts without openings.
Generally use thermosetting plastic.
Rotational molding is a process that involves the use of heat and pressure to produce hollow plastic parts. The most common type of rotational molding is called “injection molding”.
A rotational molding machine has a barrel in which molten plastic is injected and rotated to cool it evenly. The cooled, solidified part is then ejected from the machine.
In order to produce high quality parts, the temperature of the liquid plastic inside the barrel has to be maintained at a certain level throughout the entire injection process. If it gets too hot or too cold, it will affect how well the finished product turns out. This can be done by using a chiller system that cools or heats as needed.
Chillers for Thermoforming Application
Soften thermoformed sheets by heating.
Plastic extends to mold.
Plastic enters the mold under vacuum and takes shape.
Plastic thermoforming is a process which involves the heating of plastic sheets and shaping them over a mold. The shape of the mold determines the final product.
The main objective of a chiller is to maintain the temperature of the plastic at an optimal level by cooling or heating it, depending on requirements. A chiller may be used as an alternative to water baths in some cases.
Chillers are mainly used in Plastic Thermoforming for applications like:
– Injection Molding
– Blow Molding
– Vacuum Forming
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This information will help you in getting the best Injection Molding Chiller.
Indeed, it identifies everything.
That you have been searching for.
Hence, it includes version, kind, advantages, price, and maintenance, among other important points.
So before you buy a Chiller Plant For Injection Molding machine, go through this guide.
Injection Molding Chillers
The working principle of the injection molding chiller units:
After the plastic pellets are injected into the mold after heating and melting in the injection molding machine to condense, the mold is opened to eject the molded plastic workpiece.
In the continuous production process, the chilled water system of the chiller is required to cool the mold to shorten the plastic condensing time and improve the dimensional accuracy of the workpiece.
Molding quality and surface quality, this is the working principle of injection molding water chillers, injection molding water cooled chillers generally use water-cooled box chillers.
If the chiller is applied to the cooling cycle of molding molds of plastic processing machinery, it can greatly improve the surface finish of plastic industry products, reduce the surface marks and internal stress of plastic industry products, make the products do not shrink or deform, facilitate the demolding of plastic products, and accelerate product shaping.
Thereby greatly improving the production efficiency of the plastic molding machine;
Portablechiller for injection molding
What is a Chiller?
A chiller is an appliance that eliminates heat from a fluid through different methods.
They include vapor-compression, adsorption refrigeration, or absorption refrigeration cycles.
Moreover, this fluid can then be transferred through a heat exchanger to cool processing equipment or another process stream. i.e., air or process water
Chiller For Injection Molding Machine
· What are the components of a Chiller?
Following are the major components of a Chiller
Chiller system basics
· What is the principle of an Injection Molding Chiller?
A chiller performs on the principle of vapor-compression or vapor absorption closed loop.
Thus, the heat transfer takes place, the refrigerant evaporates, changing from a low-pressure fluid into a vapor.
While the Blow Molding and Molding Water proper cooling temperature of the process coolant decreases.
The refrigerant then moves to a compressor, which executes multiple functions.
How does Water Chiller Units cool the Mould.
The injection mold chiller is cooling cycle device for the injection mold machines.
The blow molding and injection molding machine cooling requirements chilled water flow rate with precise proper cooling temperature.
Injection mold coolers inject the cooling water into the mold body.
The low temperature chilled water flow rate is generated by the small process chillers.
Low-temperature water is pressurized and poured into the mold body through the booster pump to improve the cooling efficiency.
There is a pressure regulating valve on the booster pump,
The pressure regulating valve can adjust the pressure of the water flow into the injection mold, So that the cooling effect can be control;
The cooling temperature can be controlled.
· What are the kinds of a Chiller?
There are two kinds of a Chiller.
Air Chiller Diagram
What is Drooling in Water Cooling System For Molding?
When nozzles are pushed away from the mold after injection, blow molding has been processed out.
Thus, the drizzle of plastic from the sprue gate occurs.
Hence, this drizzle of plastic is usually called drooling.
Moreover, it is caused by residual pressure stored in the sprue and runner.
Water Chiller For Injection Molding Machine
How to do the water treatment in the plastic injection molding system?
When the efficiency of the chiller cooing is low, it is possible because of the scale formation.
When “hp” is used as a power unit, it is expressed by Hp (imperial horses) or Ps (metric horses), also known as “horsepower”, 1 Hp (imperial horses) = 0.7457 kW, 1 Ps (metric horses) = 0.735 kW;
· How do you set specifications of an Injection Molding Chiller?
Set injection velocity from slow
Fixed screw revolving velocity from low
Set mold open/close velocity slowly at first
Set injection proportion from a short position.
Set prolonged pressure holding time of molding appliance at first
Set a long cooling time at first.
Figure 1 Injection Molding Chiller
· How do you calculate clamping force in an Injection Molding Machine?
Clamping force is often calculated in the following ways:
Empirical FormulaClamping force (T) = clamping force constant Kp * product projected area S (CM * CM).
Empirical Formula 350bar*S(cm^2)/1000.
It is calculated using CAE software.
· What are the disadvantages of an Molding?
Disadvantages of an Molding are:
High tooling expenses and long set up lead times:
Up-front expenses are high due to the style, assessing, and tooling needed.
Firstly, there is the initial creation and prototyping.
Then the design of a prototype mold tool to produce copies of the component in proportion.
Lastly, and only after massive testing during both steps, you can finally get injection mold a component.
Part design limitations:
Components must be created with injection molding consideration and must follow the fundamentals of injection molding.
Prevent undercuts and sharp borders as much as possible
Use regular wall thicknesses to avoid inconsistencies in the cooling process resulting in issues like sink marks.
Draft angles are recommended for better de-molding.
Small runs of components can be expensive:
Due to the intricacy of processing equipment, and the need to rid the appliance of all previous material before the next product can be produced, the setup time can be too long.
Therefore small runs of parts have typically always been thought of as too costly to injection mold.
· Why is hydraulic heat exchanger used in an Chiller?
Injection Molding Chillers have a hydraulic heat exchanger mechanism.
Thus, that must give reliable execution through many years of constant, around-the-clock production cycling.
Moreover, there is also a requirement for energy control sub-circuits.
Thus, to keep the nozzle against the sprue of the mold and to keep the mold closed.
· What polymers are used in an Injection Molding Machine?
Generally, plastic injection molders use thermoplastics.
However, regular polymers used by molders are:
Acrylonitrile Butadiene Styrene (ABS),
What Are Portable Chillers For Injection Molding?
Plastic Chiller For Injection Mold Cooling
The use of a chiller for injection molding machines is one of the technological breakthroughs in the plastic industry. It is crucial to be able to mass-produce the components of plastic furniture.
In order to succeed with this manufacturing process, it requires precision and accuracy. Speed is also important.
The cooling process with the help of a small water cooled chiller chiller is crucial. In fact, experts believe that the use of water cooling system for injection molding makes up 80% of the molding process.
The use of an efficient water cooled chiller can significantly reduce the amount of time spent for each batch. It is important to evaluate your cooling needs so you can invest in the right system.
How Do You Choose Chillers For Injection Molding?
The process of cooling molten plastic is straightforward and easy to comprehend. However, it has many variables.
The main objective for choosing water cooled chiller industrial use is to find the right fit for the job. Different sized jobs have different cooling requirements.
There are 1 ton chiller, 2 ton chiller, 3 ton chiller, 10 ton chiller, 20 ton chiller, 50 ton chiller, 60 ton chiller, 100 ton chiller, 200 ton chiller, 500 ton chiller.
You can maximize your time by choosing the right chillers for injection molding.
The most important factors to consider when choosing which portable air chiller to invest in are: melting point, heat distortion temperature (HDT), desired mold temperature controller, cooling power, and the availability of space.
Portable Chiller Unit
Why Is Melting Point Important When Selecting Chiller For Injection Molding Machine?
The melting point of the plastic is an important factor to consider when choosing water mold cooling system for injection molding.
You need to understand that there are different melting points for every type of plastic. The first step is, therefore, to know what type of plastic you are working with.
It is something that you need to evaluate prior to starting the cooling process. To give you an idea, it is important to look at the types of plastic and their corresponding melting points.
Polypropylene is one of the most common types of plastic in the market. It has a melting point of 160 degrees Celsius.
Low-density polyethylene is another common type of plastic for injection molding. It has a very high melting point that can go up to 240 degrees Celsius.
Next is the high density polyethylene plastic with a melting point of up to 270 degrees Celsius.
Polycarbonate is the type of plastic with the highest melting point at 287 degrees Celsius.
It is also important to note that the melting point of plastic might vary from one manufacturer to another. Before you handle with these plastic materials, it is important to consult the manufacturer first.
Aside from knowing the heating needs of the plastic, you need to know about your goal temperature so you can decide the right portable chillers for injection molding.
Why Do You Need To Know The Heat Distortion Temperature?
The heat distortion temperature is another factor that must be taken into account when choosing air cooled portable chiller.
You need to research on the HDT range for your plastic to help you choose the right small portable chiller for the job.
Ideally, you need to chill plastic components before they reach the HDT range. If not, then the plastic components could easily deform once you take it out of the injection mold.
There are many factors within the plastic components themselves that would determine the HDT such as the composition of the plastic itself, pressure in the mold, and the molten density.
You need to talk with the plastic manufacturer so you can get the exact gauge on this and choose the right portable chillers for injection molding.
Chiller For Injection Molding
What Is The Importance Of Your Goal Temperature?
To help you decide on the best water cooling system for injection molding, you need to know the desired temperature for heating.
There is more to plastic chilling than just blasting your plastic components with cooling as soon as possible. You need to be able to optimize your temperature targets in the most efficient manner possible.
Again, you must refer to the plastic manufacturer, to learn the ideal heating and cooling temperature for the components.
This information is vital in putting together a chiller plant for injection molding machine or buying injection molding chillers.
Knowing your temperature target will enable you to select the right mold temperature so you can select your portable air chiller accordingly.
By knowing and achieving the ideal mold temperature controller, you can match that with the injecting molding chillers that can deliver such cooling capacity.
As a result, the plastic can cool and crystallize efficiently once it is molded. This will prevent cracking, seeping plastic, deformities, cavity formation, and other defects with the injection molding process chiller.
What Is The Cooling Power For In Injection Molding Chillers in the Injection Molding Process?
There are several different sizes and injection mold cooling process capacities available with portable chillers for molding cycle. They are often measured out in “tons”.
You need to look at the “tons” when comparing chiller sizes for molding cycle with plastic. It does not refer to the actual weight of the industrial chiller units.
Instead, tons indicate the horsepower of the portable chillers industrial molding. It refers to the refrigeration cooling capacity of the unit.
For example, 1 ton of injection mold cooling process power can deliver safe ejection temperature for 35 lbs per hour for polypropylene plastic or 65 lbs per hour for polycarbonate plastic.
As a general rule, 1 ton of cooling power should be enough to cool and complete the molding cycle for most types of plastic. It is something to consider when shopping around for portable chillers for injection molding process.
The injection molding process equipment is bulky. It can take up a lot of floor space in the factory. This is something to think about when choosing portable air chiller systems.
You need to know how much space is available for injection molding process so that you can size the chiller accordingly.
Water cooling system for molding cycle take up more space than air cooled portable chiller. This is because the former will require the use of cooling towers.
It is also the reason why a portable air chiller makes most sense in this injection molding applications. Since it is not fixed into position, you can free up the space once you are done with injection molding.
Chiller Package Unit Small Space
What Else Require Cooling During Injection Molding?
Relying on portable chillers for injection molding has its own benefits that will facilitate ease of plastic manufacturing.
There are also certain limitations to the cooling capacity of a portable air chiller. It might not be enough to provide the cooling you need.
You need to keep in mind that during the plastic processing, the injection molding equipment is not the only one that will require chilled water injection mold cooling process. There will be other processing equipment that will be in use that will generate heat in the water loop.
During plastic molding, refer to the temperature to the process, the following equipment must be cooled as well: hydraulic heat exchanger motor, feed throat, thermometer, dryer aftercooler, and hot runners.
It is important to determine how much the equipment would heat up during plastic molding. This will enable you to choose the best chiller plant for plastic molding machine and other equipment.
What Features Do You Look For In Portable Chillers For Injection Molding Process Cooling?
General Plastic Manufacturing Mold Cooling
The best way to choose the best portable chillers for plastic molding is to look at the features you need.
Make sure that the small portable chiller you buy has the following features: quiet compressor, Screw compressor, scroll compressor, recirculation, efficient cooling fluids, precise temperature controls, customization, and flexible temperature ranges.
A quiet compressor is a must when choosing the best portable chillers for plastic molding. This is important so you can reduce the noise within the plastic molding facility.
If you are looking for injection molding chillers with a quiet compressor, make sure to avoid reciprocating compressors. They are the loudest to operate when compared to other types of compressors.
Injection Molding Chillers
The ability to precisely control temperature is another important factor to consider when buying injection molding chillers.
It goes without saying that getting your temperature right is vital to the success of injection molding in plastic. You will be able to be efficient with plastic molding if you control the temperature correctly.
The efficiency of the cooling fluids for water or air-cooled chiller is also important. The best cooling fluids for this purpose, are those with water and glycerol since they facilitate in effectively removing waste heat.
Chiller System Basics
Flexible temperature ranges is also an important consideration when buying chiller for injection molding machine. There are several areas that plastic molding can go wrong. However, these variables are highly dependent on the temperature.
The ability to control the temperature during the plastic cooling process is important. This will enable you to achieve the optimum cooling requirement based on the plastic selection.
Finally, you want a water chiller for injection molding machine that can be easily customized. Each injection molding job is unique. Make sure you can tweak the controls and the function of the chiller to suit your needs.
Industrial Water Chiller
What Are The Benefits Of Plastic Cooling With Chillers?
The use of cooling technology is definitely a game-changer when it comes to the plastics industry.
This innovation has brought about many benefits in terms of how plastic products are manufactured.
First off, it has helped reduce cooling times so that it can speed up the manufacturing process cooling. With less cooling time, it means you can mold more plastic in the same amount of time.
Water Cooling Towers
It can also deliver better quality for your molded components. By efficiently cooling the plastic, you can reduce the possibility of having defects on the plastic material once you take it out of the mold.
The final advantage of using water cooled chiller for injection molding is the reduced costs and higher efficiency. There will be less waste and the processes can be accomplished using a shorter amount of time.
Is Water Or Air Chilled Cooler Better For Injection Molding?
There are two systems to choose from when it comes to choosing a water cooled chiller for injection molding machine: water- or air-cooled chiller, also can use cooling towers.
The decision on which of the two systems to buy will depend on your own needs as there will be certain benefits and drawbacks for each system.
Air Cooled Chiller Diagram
Injection molding is a complex process, one of the basic requirements of plastic injection molding is proper cooling, for which we mainly use water. Chilled water is often the preferred coolant because of its low cost, excellent heat transfer properties, and easy availability.
– The water used to cool our injection molding machines must be chemically treated to prevent bacterial growth, scaling or contamination of the entire system.
Two water treatment methods: The first is a tower system that maintains the water temperature around 70 o – 90 o F. This system is used to keep the machine at a safe operating temperature. The machine must be cooled to maintain maximum oil temperature and reduce feed inlet temperature. The feed port is where the plastic is fed into the heated barrel, and the temperature needs to be controlled to prevent premature melting of the plastic as it transitions from solid to molten plastic.
The second is the cooling water system, which is maintained at a more stable 50 o F temperature. The system is used to cool tools. Chilled water is directed through molds and tooling to remove heat from the injected plastic as quickly as possible. Cooling is often the longest part of a production cycle, so reducing wait times is beneficial. In most cases, we try to bring the plastic down from about 500 o F to 100 o F to 140 o F as quickly as possible.
GESON 120 ton chiller system to improve cold water distribution throughout the plant. This system helps maintain a consistent 50 o F water temperature distribution throughout the facility and provides our tools when needed.
To achieve the optimum mold temperature, possibly higher than the chilled water supply temperature, we use a mold thermostat, which increases the water temperature in a small closed loop system that pumps water through the mold. Using these, we can run different temperatures at each machine location. Each thermostat has a separate valve that lets in a small amount of cold water and releases some hot water to maintain a stable temperature.
The process water temperature is different for each mold and is determined by a number of variables. The wall thickness of the part, dimensional requirements, the type of resin used, and dimensional factors in the mold design can all affect the process water temperature.
Extreme conditions sometimes call for temperatures too high to use tap water safely. In these cases, we would use a hot oil thermostat and then use chilled water to maintain the temperature of these oil units through a heat exchanger.
It is also important to note that water cooled chillers will require the installation of a cooling towers. Take this additional cost to mind when choosing what water cooled chiller system to use for plastic molding.