Industrial Chillers for Metal Finishing

Industrial Chillers for Metal Finishing

Cold Shot Chillers® manufactures and installs the best cooling solutions for your metal finishing needs.

Finishing for forged metal parts is vital to manufacturing high-quality products that can withstand the rigors of industrial and commercial use. Anodizing (electrochemical metallic oxide deposition), plating, and welding generate significant amounts of heat and therefore require cooling systems.

Industrial chiller manufacturers like Cold Shot Chillers® provide efficient metal finishing chillers for different applications.

Applications of Metal Finishing Chillers

Metal finishing processes typically produce significant quantities of thermal energy, which can adversely affect the quality of finished products if not properly dissipated. Several industrial cooling options exist to cater to the heat created during these metal finishing procedures.

Outlined below are some applications where metal finishing chillers are vital.

  • Laser cooling
  • Anodizing
  • Paint and powder coating
  • Quench cooling
  • Furnace cooling
  • Induction furnace coil cooling
  • Die casting cooling
  • Spot welding
  • Waterjet cutting
  • Plasma cutting
  • Thermal spraying

Anodizing Cooling System

Anodizing a metal part refers to processes that coat its exterior with a metallic film. The metal component to be treated is designated the anode of an electrolytic cell which also contains a cathode made of another element. These components are submerged in a chemical bath.

When an electrical current is passed through the setup, it dislodges metallic ions from the cathode and deposits them as a film on the anode. The deposited layer’s thickness depends on the anode’s duration of exposure within the electrically charged bath.

As earlier stated, the anodizing process will generate a significant amount of heat that must be eliminated to ensure effective and even metallic oxide deposition.

Cold Shot’s metal finishing chillers can effectively maintain anodizing temperatures at optimal levels. Using water or air-cooled chillers alongside the electrochemical vats can achieve this result.

How Does an Anodizing Cooling System Work?

For metal cooling systems that utilize air or water-cooled chillers, alterations in the temperature within the anodizing vessel are detected by a thermal sensor fitted within.

When the amount of heat generated by the anodizing process begins to rise above predetermined levels, controlling valves in the chiller system are opened. This allows coolant to flow through the heat exchanger, causing the internal temperature to drop. These valves will also automatically shut off when optimal temperature ranges have been attained, preventing the electrolytic process’s overcooling.

Spot Welder Cooling System

When resistance electrodes are used for welding a joint, the heated electrodes are subjected to very high temperatures within a very short period. Therefore, using water-cooling systems will prevent the electrodes from undergoing premature burnout.

Typically, a water tube located within each electrode is used to maintain the welding temperatures at a stable state, inhibiting electrode breakdown and poor weld strength.

Quench Tank Cooling

This technique of metal cooling involves the complete immersion of the material into a container surrounded by a heat exchanger. Heat transferred from the metallic part to the cooling tank is dissipated by the thermal exchanger through which a coolant (usually a mixture of glycol and water) from a chiller unit is circulating.

Die Cast Cooling System

Metal forging in various shapes and designs is a process that requires close thermal regulation to ensure optimal results. The typical setup for die-casting cooling systems includes a cooling basin/mold into which the molten metal can be poured. Attached to this vessel is a heat exchanger that circulates chilled fluid, pulling heat away from the process.

Induction Furnace Cooling System

Various methods are currently being employed to achieve induction cooling. Most industrial induction cooling equipment uses a closed-loop setup that conveys air or water within a heat exchanger surrounding the manufacturing process.

Like other cooling systems that function with heat exchangers, induction furnace cooling systems typically utilize a glycol-water mixture as a coolant. This water-cooled induction heater will help to attain the desired thermoregulation.

Waterjet Cutting Chillers

Waterjet cutting chillers are specifically designed for the water usage of your waterjet machines. Manufactured of the highest quality components, they are designed to run efficiently by maintaining precise water-cutting temperatures.

Designed for quiet operation, our ruggedly dependable waterjet chillers are available in standard or custom specifications. Available in 2 and 3 ton, our waterjet cutting chillers are highly cost-effective and are custom designed for your specific water-cutting machine operations. In addition, they can withstand the most hostile environmental operating situations. Learn more about our Standard Flow Air Cooled Portable Chillers and Standard Flow Water Cooled Portable Chillers

Plasma Cutting Chillers

The plasma-cutting process uses an accelerated jet of hot plasma to transfer energy to an electrically-conductive work material. Plasma cutting is commonly utilized in industrial construction, fabrication shops, salvage and scrapping operations, and automotive repair.

Industrial cooling systems are used in these applications to give stable temperatures during the plasma-cutting procedure. Our chillers maintain the integrity of the plasma cutting system with exceptional performance, offering years of reliable liquid temperature control.

Thermal Spray Chillers

Thermal spraying is a coating technique that improves the surface of a solid material. During the process, fine particles of a heated substance are carried in a stream of working gas and sprayed onto the component to create a uniform, finished coating.

To achieve high-quality final products, industrial chillers are employed to maintain the temperature during the thermal spray process. Chillers control the spray nozzle temperature to prevent overheating or over-cooling, maintaining the precise temperature throughout operation.

Metal Finishing Chiller Sizing

To determine the chiller size needed for your metal finishing operation, follow this formula:

  1. Obtain output of rectifier (Amp & Volts)
  2. Obtain total BTUs (Total BTUs = Amps x Volts x 3.414)
  3. Calculate tons of cooling capacity (Tons = BTU ÷ 12,000)
  4. Size chiller by rounding up to the closest standard unit size

For example:

  1. Rectifier output is 1,000 Amps & 24 Volts
  2. Total BTU’s = 1,000 x 24 Volts x 3.414 = 81,936
  3. Tons = 81,936 ÷ 12,000 = 6.83 tons
  4. This application will require a 7.5-Ton unit

Cold Shot Chillers Can Support Your Metal Finishing Needs

For over thirty years, Cold Shot Chillers® has maintained a high level of professionalism while manufacturing and delivering its clients the best commercial chillers in the industry. Our metal finishing chillers are built using high-quality materials to ensure your satisfaction. Most chiller designs 2-20 tons in capacity ship 1-2 weeks after receipt of order, 25-100 ton capacities ship in 3-4 weeks.

If you’re interested in learning more about the different chiller options we offer, please request a quote toda

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