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
