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    Chiller Sizing Formulas: Injection Molding Extrusion

    Uploaded by

    Varathasankar Arumugam
    This document provides formulas for sizing chillers and cooling systems for various industrial manufacturing processes such as injection molding, extrusion, blow molding, and die casting. It lists cooling load requirements in tons for different materials and processes, such as 30-60 lbs/hour per ton for various plastics in injection molding. It also provides formulas for calculating cooling needs for equipment like extruders, mixers, vacuum forming, hot runners, and more.

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    © All Rights Reserved
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    Chiller Sizing Formulas: Injection Molding Extrusion

    Uploaded by

    Varathasankar Arumugam
    191 views3 pages
    This document provides formulas for sizing chillers and cooling systems for various industrial manufacturing processes such as injection molding, extrusion, blow molding, and die casting. It lists cooling load requirements in tons for different materials and processes, such as 30-60 lbs/hour per ton for various plastics in injection molding. It also provides formulas for calculating cooling needs for equipment like extruders, mixers, vacuum forming, hot runners, and more.

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    Chiller Loadsizingformulas

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    This document provides formulas for sizing chillers and cooling systems for various industrial manufacturing processes such as injection molding, extrusion, blow molding, and die casting. It lists cooling load requirements in tons for different materials and processes, such as 30-60 lbs/hour per ton for various plastics in injection molding. It also provides formulas for calculating cooling needs for equipment like extruders, mixers, vacuum forming, hot runners, and more.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    191 views3 pages

    Chiller Sizing Formulas: Injection Molding Extrusion

    Uploaded by

    Varathasankar Arumugam
    This document provides formulas for sizing chillers and cooling systems for various industrial manufacturing processes such as injection molding, extrusion, blow molding, and die casting. It lists cooling load requirements in tons for different materials and processes, such as 30-60 lbs/hour per ton for various plastics in injection molding. It also provides formulas for calculating cooling needs for equipment like extruders, mixers, vacuum forming, hot runners, and more.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 3

    CHILLER SIZING FORMULAS

    INJECTION MOLDING

    EXTRUSION
    SHEET CALENDERING

    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

    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 HOLDING

    VACUUM 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

    BLOWN FILM LOAD SIZING


    100 CFM
    100 CFM
    100 CFM

    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

    Entering Air Conditions


    A Guide to calculate the DIE CFM:
    1 3 cfm / lb.
    2 150 to 170 cfm / inch

    90 F dry bulb / 78 F wet bulb


    Includes blower motor heat

    HOT RUNNER MOLDS:


    convert heater watts to btu's and divide by 2. (watts x 3.414 divide by 24,000 Btu

    MIXER:
    lbs/hour x .5 x temp. difference + 0.2 hp. = tons
    12,000 Btu/ton

    VACUUM FORMING:
    (temp. sheet on - temp. sheet off) x S.H> x lbs/hour = tons
    12,000 Btu/ton
    * S.H. is specific heat of plastic.
    * Approx. temp. in 220 F. and temp. out 100 F.
    * Sheet is cooled by the surrounding air, lbs/hour may be increased by 10%

    COOLING & HEATING LOAD:


    lbs/hour x (temp. start - temp. end) x S.H. = BTUs
    * S.H. is specific heat of material.

    MOLD HEAT UP TIME:


    weight (lbs) x (temp. start - temp. end) x S.H. = Time in Hrs.
    heater capacity (Btu's)
    * S.H. is specific heat of mold material.

    PLATING BATHS:
    DC amps x DC volts x 3.414 x 75% eff. = Tons
    12,000 Btu/ton

    FOR TOWER WATER


    COOLING TOWER SIZING
    Hydraulic Cooling
    Vacuum Pump
    Rubber Mills
    Gear Drives
    Water Pumps
    Air Compressor oil
    Air Comp. after cooler
    Spot Welders
    Chiller Condenser

    GENERAL FORMULAE

    .11 hp / ton
    .1 hp / ton
    .1 hp / ton
    .1 hp / ton
    .2 hp / ton
    .16 hp / ton
    .2 hp / ton
    100 kw / ton
    1 ton = 1 ton

    To run any of the above equipment on a chiller multiply the


    tower cooling load by 1.25.

    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
    Tower Water Range summer 70 F to 85 F, winter a low of 50 F to
    85 F
    TD - Temperature Difference (between in & out

    DIE CASTING:
    Zinc - lbs/hour x 35 btu/lb. = Tower Tons
    15,000 Btu/ton
    Aluminum - lbs/hour x 325 btu/lb. = Tower Tons
    15,000 Btu/ton

    *(pour at 800 F. Remove at 600 F.)

    * (pour at 1200 F. Remove at 600 F.)

    STEEL QUENCHING:
    Continuous - lbs/hour x 0.166 x (temp. in - temp. out) = Tower Tons
    15,000 Btu/ton
    Batch - lbs/load x 0.166 x (temp. in - temp. out) = Tower Tons
    Quench time (hrs) x 15,000 Btu/ton

    FAN BEARINGS:
    TRANSFORMER COOLING:
    MOLD ROOM COOLING:
    TRANSFORMER COOLING:

    0.2 ton/fan motor (2 gpm/fan motor)


    1 KVA = 1 ton
    80 sq. ft./ton (16' ceiling)

    1 KVA = 1 ton
    * To use any of the above on a chilling system use 12,000 Btu instead of 15,000

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