Chiller Solutions to Match batching plant Brands
Why Choose Our Batching Plant Chiller
- Chillerone possesses quality certification systems such as CE, SGS, and ISO.
- Chillerone is equipped with advanced production and processing equipment, including CNC presses, among other precision devices.
- Our annual production capacity is 9,000 chillers.
- Our water chillers come with a 12-month free warranty.
- Chillerone can customize product design according to your specific requirements.
- Our products are sold in 75 countries and regions around the world.
Your Reliable Batching Plant Chiller Supplier
The Chillerone concrete cooling unit is made for jobs that involve concrete. It is used during concrete mixing, dam pours, and road work. Our plant chiller can handle cooling from 30 to 200 tons. It can also keep the concrete mix temperature steady at 70°F to 90°F by cooling the mixing water. This helps keep work quality on track when the days are hot.
Chillerone has worked in industrial refrigeration for more than twenty years. We have two manufacturing sites in Shenzhen and Dezhou. We also have a lab at the national level.
Now, come and get a free consultation!
Our Products
The system uses air to cool. You do not need a cooling tower. You also do not need a water supply. That lets you set it up in more places.
It cools with water, so it works better. It also fits well for running big mixing sites for a long time.
It is small and easy to carry. Good for short jobs or moving between work sites.
The unit is built to keep cold water flowing without big ups and downs. It is meant for mixing plants that run at a large scale.
It uses one main cooling system. That system supports several production lines. Each line runs under the same basic control setup.
Chillerone can be customized to meet any of your specific requirements, providing a batching plant chiller tailored to your specific working environment.
Precise & Stable Temperature Control
We use a concrete mixing cooling setup with heat exchange tubes on both sides. The system can hold the water temperature within plus or minus 1 C. The water leaving the unit shows only a very small change in temperature.
Even when the outdoor temperature shifts, or when the production load moves up and down, the supply stays steady. It keeps feeding low-temperature cooling water. Therefore, we can ensure that each batch of your concrete maintains high strength and durability.
High Cooling Capacity for Continuous Batching
Chillerone offers a chiller for concrete batching plants. The cooling output ranges from 30 to 200 tons. So whether you run a small concrete batching plant or a big RMC site, our concrete water chiller can handle what you need for output. The unit keeps sending a steady flow of chilled water. Cooling stays stable when production is high. It also holds up during very hot summer days.
Reliable Operation in Hot & Dusty Environments
Concrete mixing plants often operate in harsh environments, and your equipment may be exposed to various risks such as wind, sand, rain, and rusting. The Chillerone system for cooling concrete is built with parts that resist corrosion. It also has a dust-tight design to help keep grit out. In hot weather and dusty work areas, it keeps running. The unit is rated IP55 for overall protection. Important parts are rated IP65. This setup helps your concrete batching equipment stay dependable over time.
Applications of Batching Plant Chiller
Big jobs like dams often need nonstop days of concrete work. Chillerone’s systems keep a constant flow of chilled water for the mix. That steady cooling helps the concrete stay cooler as soon as it gets poured into the formwork. It can also reduce the risk of thermal cracking.
The mixing station has to run all day and night. The concrete chiller system provides cold water nonstop. Because of that, the temperature stays steady in every truckload of concrete when it leaves the machine. This helps meet what is needed for pouring at the job site.
Pipe piles, blocks, and wall panels are made in large runs at the plant. A water chiller keeps the mixing water at the same temperature each time. That helps the batches set with steady strength and the same overall quality.
In summer, when temperatures are high, our batch plant chiller can send cold mixing water to the job site. This helps keep the concrete from getting stiff too soon. This can help your concrete pour go smoothly.
- Make sure the power at the site is steady. Confirm that the voltage and the frequency match what the unit needs.
- Next, attach the inlet pipe for water. Then connect the drain outlet.
- While doing this, leave enough room around the unit. Also make sure there is proper airflow for cooling.
- If you are buying a water-cooled concrete water chiller, plan for a cooling tower too. You will also need a suitable water supply.
The standard model chiller has a water buffer tank inside. This tank helps keep the water outlet temperature steady. For short, off-and-on cooling at your mixing station, this setup is usually enough.
If you are working on a bigger job, plan for an extra storage tank too. Doing this can raise the cooling capacity. It also helps manage the ups and downs in water demand during busy times.
- Clean the condenser fins and the water filter about every 3 months.
- Also check the heat exchanger and the water pump every 6 months.
- At the same time, look over the refrigeration system.
- Once a year, carry out full maintenance on the whole unit.
- If the water at your site is hard, or if there is a lot of dust in the air, do these tasks more often.
You can adjust the concrete chiller system settings, such as the cooling output, the outlet water temperature, and whether it uses air or water cooling. You can also choose a portable or fixed unit. The material, the control setup, and the power details can be set to match what you need.
Send us the on-site conditions and your production needs. After that, our engineers will take care of the remaining work. They will also help you work out the right setup.
Tell us these items: the mixing station hourly output, the outlet water temperature you want, the local air temperature, and how many hours per day you will run the system. Also share what the current water source is and its water temperature. Include the power details too, like the voltage and frequency. Finally, tell us where it will be placed, indoors or outdoors. Once we have this, we can prepare a clear and correct quote.
Why Does a Concrete Batching Plant Need a Chiller to Cool?
A concrete mixing station uses a water chiller because the cement generates heat as it reacts. When the mixing goes on, the concrete temperature can keep climbing. If it rises too much, it may start several knock-on effects, such as:
- Hot weather speeds up the slump loss. The mix can get thick sooner than expected. Then pumping and placing become harder.
- Heat can also ruin the timing. If it is too warm, the concrete starts to set fast. It may stiffen before the truck even reaches the site.
- There is a bigger crack problem in large pours. Heat builds up inside, but the outside stays cooler for longer. This uneven cooling can leave the concrete under high stress. Cracks can form more easily.
- Strength and life of the concrete can drop too. High temperatures push the hydration process to move fast. The cement paste can end up less tight. In the end, strength is reduced, and long-term durability is not reliably met.
The function of the industrial water chiller is to:
The batching plant chiller cools the water that is used in the mix. It does this by running the water through the refrigeration part of the system. After that, the cooled water comes out through the heat exchanger. Then it is kept in a storage tank. From there, the chilled water is sent in a steady flow to the mixing station. Cooling occurs while the mix is happening. As the materials combine, heat leaves the workpiece little by little.The mix water that leaves the unit stays at a safe range. This also keeps you from the problems mentioned before. If a concrete plant has to run for hours and the water needs cooling, a chiller is a steady option. It is easy to operate and it fits large jobs that last.
A Simple Look at How to Pick a Concrete Water Chiller
Start with the Job Details
First, determine the hourly output and water consumption of the concrete factory.
With those two values, you can begin estimating.
Choose the Water Temperatures
Look at the hottest water temperature you get at the inlet during summer at your site. Then decide what water temperature you need at the outlet for your process.
If ΔT ends up higher, the chiller in the concrete batching plant has to take away more heat from the water each hour. For that reason, you will need more cooling capacity to handle it.
Estimate the Cooling Load
First, work out the cooling duty needed to bring the water down by the target amount. A basic estimate is:
Cooling capacity (kW) = (water rate, kg/h) × (water heat value, 4.2 kJ/kg·°C) × (ΔT, °C) ÷ 3600
This estimate is just a quick way to judge the load. It mainly looks at cooling the mixing water. It can help with the first try at equipment sizing. But it misses part of the real picture. A chiller for a batching plant has to handle heat losses, the top flow you may see during running, and how pipes and parts behave once things are set up on site. Before you buy or finalize anything, let an engineering team check the numbers and the setup.
Next, Consider the Installation Conditions
Air Temperature
If the condenser area stays warm, the unit cannot dump heat as well. In that case, the real cooling output can be less than what the rating sheet says. When you choose a unit, use the highest summer air temperature you expect on the site.
Placement and Air Flow
Give the unit room. Keep space open near the air intake. Do not put panels, boxes, or other items right by the intake side. If you block the airflow path, heat exchange will drop.
If you use water cooled equipment, also look closely at the cooling tower layout. Check that the water supply on site can support the chiller system needs.
Electrical Power
Start by checking site voltage. Make sure the site data lines up with the unit limits in the design.
Water Quality
Check the water quality of the location where your project is situated. This determines the material of the chiller you ultimately choose.
Review the Placement Limits
The heat load you worked out is just a first estimate. Choose a chiller that is a bit larger than that early figure. After the engineering team finishes the full heat load check, go back to the sizing. Repeat the look using peak water use, expected heat losses, and the day to day swing in system operation. Also factor in the real conditions on site. When you have those points, pass the operating details to the maker.
They can then tune the unit so it fits the actual conditions better.
Think About Water Storage and How the System Is Laid Out
The water entering the mixing unit does not move at one steady rate. Because of that, the chiller often struggles to follow the demand in a smooth pattern.
The chiller cools the water at a steady output. Then it charges the tank with chilled water. When mixing starts, the system can pull from the tank right away. It does not need to wait on the incoming line. As a result, the water temperature stays more stable. It also means the chiller does not need to be sized only for brief top peak moments.Tank size is not a single choice you pick once. It depends on the highest water draw rate. It also depends on the chiller cooling capacity. And it depends on how the site load will change over time.
The engineering team should set the tank size after they review the actual job layout. The pump choice, pipe insulation, and the control approach must be matched.
What Temperature Should Concrete Be Cooled to While It Is Still Being Mixed?
There is not one magic cooling temperature for every concrete mix.
Below are typical targets and the main things to pay attention to. Use them as a guide when you set your cooling controls.
Typical target ranges
Chilled mixing water: 0 to 10°C. This is the main goal for the cooling setup. Some stricter projects choose 0 to 2°C. Others plan in the 4 to 7°C range.
Concrete just after mixing, at the mixer exit: 5 to 26°C.
Concrete when it gets to the formwork: about 28 to 30°C or less. This is checked during the pour to keep quality in line.
What Is the Difference Between the Water Chiller and the Flake Ice System?
Both water chillers and flake ice units reduce concrete temperature. They are chosen for different job needs.
Concrete Water Chiller
A concrete chiller lowers temperature in a direct way. It pulls heat by cooling the mixing water. Most systems chill water to about 1°C to 10°C.
It is simple to run. The temperature drop stays steady. It also fits long, steady work periods. That is why it is common in ready-mix plants and in precast work.
Flake Ice Slab System
A slab setup uses a phase change. When it is extremely hot, such as above 45°C, slab cooling can make a difference. The same holds true when you pour big amounts of concrete at one time. With slab ice, the mix can be chilled more. It also helps the mixer stay at a lower temp for a longer period. In these cases, the result can be better than relying only on a chiller.
Main drawback:
The work is harder to set up. You need an ice maker. You also need a place to store ice. Then you need a way to move the ice to the job site.
Quick pick
If you only need moderate cooling, a concrete chiller is often enough.
If cooling demands are high, ice slab systems fit better. This can apply to hot desert work. It also applies to large dam pours.
For tough jobs, you can run more than one method together.
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