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The Specific Application of Water Chillers in Carbonated Soft Drink Production
In the production of carbonated soft drinks, a water chiller is not merely a cooling device, it is a critical component for ensuring product quality, consistency, and production efficiency. Its application is centered on one key principle: the solubility of carbon dioxide (CO₂) increases as temperature decreases.
The chiller system is typically integrated into three core stages of the production line:
1. Base Water Cooling (Pre-carbonation)
The process begins with treating and cooling the base water. After filtration and deaeration (removing oxygen to prevent off-flavors), the water must be chilled to a precise temperature, typically between1°C and 4°C (34°F to 39°F). This is the primary function of the industrial chiller.
This low temperature is the prerequisite for efficient carbonation. Cold water absorbs and holds CO₂ gas far more effectively than warm water.
Without this step, achieving the required "volumes of CO₂" (the standard measure of carbonation) would be impossible, resulting in a flat, inferior product.
2. Carbonation and Mixing (The "Proportioner" or "Metering" Stage)
The most critical application is within the proportioner, a sophisticated machine that combines the chilled water, syrup, and CO₂. This unit often has its own integrated or dedicated chiller loop to maintain ultralow temperatures.
The mixture is often held at temperatures as low as 0°C to 3°C (32°F to 37°F).
The Process:
The chilled water and syrup are precisely metered and mixed.
The mixture then enters a carbonation tank or a "carbonator."
CO₂ gas is injected under pressure (typically 40-60 psi) into the cold mixture.
The combination of low temperature and high pressuremaximizes CO₂ absorption, ensuring the final product has the sharp, crisp "bite" and stable foam characteristic of a high-quality carbonated beverage.
3. Flashing Prevention During Filling
After carbonation, the beverage is transported to the filler. If the temperature rises, the CO₂ will rapidly come out of solution-a phenomenon known as "flashing."
The chiller maintains the beverage at a consistently low temperature throughout the filler bowl and the filling process.
This prevents the formation of excessive foam during the high-speed filling of cans or bottles. Foam can lead to underfilled containers, wasted product, and a significant slowdown in production line speed (measured in bottles per minute, or BPM).
System Design and Requirements
To achieve these goals, the water chiller system in a carbonated soft drink facility has specific design characteristics:
High Cooling Capacity:Large production lines require massive cooling power. It is common to use a centralized chilling system with multiple screw or scroll compressors to provide a stable supply of chilled water (or a glycol-water mixture) to multiple production lines simultaneously.
Precise Temperature Control:Even minor fluctuations in temperature directly affect CO₂ absorption. Therefore, the chiller system must offer high-precision control, often maintaining the target temperature within ±0.5°C to ensure consistent carbonation levels across every batch.
Food-Grade Materials:All components that come into contact with the water or beverage-including the chiller's heat exchanger, pumps, and piping-must be constructed from304 or 316L stainless steel. This prevents corrosion, ensures hygiene, and meets strict food safety regulations.
Integration with Buffer Tanks:The system usually includes large, insulated buffer tanks that store a reservoir of chilled water. This allows the chiller to run steadily without constantly cycling on and off to meet peak demand during high-speed filling, improving energy efficiency and component longevity.
In summary, the industrial chiller is the backbone of the carbonated beverage production process. It enables the thermodynamic conditions necessary for CO₂ solubility, ensures astable and consistent product, and allows for thehigh-speed, efficient fillingthat defines the modern beverage industry.
Here we check a project from the customer
9000L/hr sprite from 25degrees down to 4degrees, customer required water cooled chiller, which needs to connect cooling tower.
For the glycol side cooling capacity calculation, we choosed cooling capacity= 9m3/h*(25-4)/0.86*1.1=242kw, based on 2C outlet.
The plate heat exchange design: 9000L/hr sprite 25degress inlet and 4degress outlet, glycol side 42m3/hr 7degrees inlet and 2degrees outlet.
Let's see whole water chiller cooling tower system working princinple
Here let's see the glycol water chiller system specs:
|
Item |
Specification / Supplier |
||
|
Cooling capacity |
Model |
AYD-250WS |
|
|
kw/hr |
247.9 |
||
|
Power input |
kw |
68.1 |
|
|
Current |
A |
115.1 |
|
|
Power Supply |
380V-3N-50HZ |
||
|
TempOutlet (℃) |
0-2 |
||
|
refrigerant control |
Expansion valve |
||
|
Refrigeration circle |
1 |
||
|
refrigerant |
R407C |
||
|
Dimension(mm)L*W*H |
3500*1000*1800 |
||
|
Compressor |
style |
Screw |
|
|
Model |
RC-340B |
||
|
Qty |
1 |
||
|
Compressor power(kw) |
68.1 |
||
|
Condenser |
Style |
Shell and Tubes/1set |
|
|
Chilled water flow(m3/h) |
54.3 |
||
|
Pipe size(") |
4 |
||
|
Evaporator |
Style |
Stainless Steel Shell and Tubes/1set |
|
|
Cold water flow(m3/h) |
42.6 |
||
|
Pipe size(") |
4 |
||
|
Protector Device |
1,Phase protector 2,Flow protector 3,High/low voltage protector 4,Coil overheat protector 5,Anti-freeze protector |
||
|
Unit Weight(kg) |
2450 |
||
|
Main PartsBrand |
|||
|
Compressor |
Hanbell |
||
|
Electronic |
LS / Chnt |
||
|
Expansion Valve |
Emerson |
||
|
Electrical Control |
Siemens/Punp |
||
Remark: The cooling capacity is based on outlettemperature 2C, condensing temperature 40C.
RFQ:
1.Before confirming a model, which info do we need?
soft drink output per hour, temp change, which cooling type.
2.Which refrigerant do you often adopt?
R407C, R410A, R404A and R449A.
3.It is ok for ustomized?
Yes, anti-corrosive area, vsd driven, split system like remote air condenser, remote control and anything you asked we will give you our solutions.
4.Application of the glycol water chiller?
beverage cooling, milk cooling, brewery cooling, ice rink cooling, ice cream cooling and so on.
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