Falling Film Chiller

Falling Film Chiller Process reliability to produce constant cooling of ice water near freezing point

Falling Film Chillers, also referred to as the baudelot ice water coolers, is intended for continuous cooling water close to the freezing point at 0.5°C constant temperature as desired temperature. To prevent ice formation on the panels, it's necessary to regulate the suction gas pressure at the evaporator suction header and to ensure efficient cooling. Additionally, it's important to maintain the evaporation temperature, which should not fall lower than -3°C, and monitor the water temperatures and flow rate. If the system uses glycol, it's necessary to control the glycol inlet temperature.

Cold water has a high heat capacity, which means that it can carry a large amount of heat with relatively small quantities compared to other cooling agents. This makes it an effective choice for industrial water chillers. Water's flow-specific and thermodynamic parameters are favorable for achieving high heat transfer rates. The freezing point of water is important when making and using cold water for cooling purposes. To maximize the temperature difference and keep the product being chilled as cold as possible, it's necessary to get the temperature of the water as close to its zero point as possible.

What’s a Falling Film Chiller?

How does a Falling Film Chiller work?

The Baudelot ice water cooler, also known as the Falling Film Chiller, is a highly efficient custom made cooling system for process water. It consists of a distribution tray, a heat exchange system of plates, a frame, and a cover, along with an optional bottom collecting tank. Water is pumped into the distribution tray and evenly distributed over vertical panels, allowing for maximum heat transfer. The thin film of water flows or water falls down the plates as a thin layer, achieving high transmission coefficients and an optimal outside film coefficient. Upgrade your cooling requirement with the Baudelot ice water cooler as suitable solution for improved process efficiency.

A high flow velocity guarantees the high efficiency of ice water and kind of self-cleaning down the plate, even with contaminated liquids. The use of stainless steel ensures compliance with all sanitary requirements, as the ice water contacts only AISI 304 or 316L stainless steel parts, as well as higher-grade stainless steel up to titanium. This ensures both cleanliness and durability, while also providing high-performance operation.

Industrial Ice water chiller in dairy processes

A Falling Film Chiller, also known as a Baudelot ice water chiller, is a machine that can continuously produce cooled water at 0.5°C without forming ice on the plates. This makes it the perfect cooling medium for milk-processing plants. Not only is ice water non-toxic and has excellent heat transfer and transport properties, but it is also an inexpensive and widely available resource. With the goal of meeting high global quality standards, it is crucial to ensure fast and smooth cooling processes from processing to storage of sensitive dairy products such as milk, milk powder, yoghurt, milk desserts, butter and cheese, even if it comes at the expense of high energy costs.

Milk processing plants can save costs and space by partnering with companies like Refrigeration AG for ice water technology. Rather than installing additional ice water storage tanks, it's more efficient to use a Falling Film Chiller for ice water pre-cooling. This not only saves money but also generates ice water temperatures between 0°C and 1°C without any risk. Falling-Film Chillers cool returning water and relieve existing plant systems with their robust, simple operation and high energy efficiency. Find out how Refrigeration AG can help your dairy expand its capacity while reducing costs.

Industrial Applications for Industrial Water Chillers

What’s the Process?

The Falling Film Chiller or Baudelot Industrial Water Chiller is a powerful tool for efficiently chilling water down to 0.5°C even for s short period. It can be used as a pre-chiller for industrial ice bank systems, connected to the ice water side of a Plate Heat Exchanger, or pumped directly into various food cooling processes. The homogeneous falling film ensures maximum efficiency, while the water collecting tank and pumps make it easy to bring chilled water to any location. Whether you're in the food industry or another industrial process, the Falling Film Chiller is a reliable and effective solution for all your water chilling needs.

Process water chiller with discontinuous inlet water flow

Our Falling Film Chiller, also known as the Baudelot ice water cooler, is designed to cool water with discontinuous or changing flow rate temperatures. Our split-tank-design allows for continuous operation of the evaporator, ensuring optimal performance for your refrigeration machine. The water reservoir with flow path is custom-designed to match the flow profile and water temperatures, making it robust to unexpected fluctuations. Our exclusive use of stainless steel meets all the requirements for a food-grade design, ensuring that your Ice Water Falling Film Chiller is safe for use in any food service environment. Choose our Falling Film Chiller for reliable, efficient, and safe cooling of your water supply.

De-oiling device of an industrial water chiller

The Falling Film Chiller is a top choice for refrigerant NH3, as it features a standard de-oiling device to improve efficiency. A small suction pipe for gravity or pump operation is located at the liquid bottom header of the system. For CO2, this device is available upon request. However, there are potential solubility gaps with different oils, even with helpful additives. To ensure optimal performance, regular de-oiling is required, which is determined based on the properties of the refrigerant compressor and the oil used. Our experienced engineers, with academic advice, are responsible for the design of each project, which includes an individual channel design and construction. This is due to the high inside film coefficient and low pressure drop of the system.

The Baudelot cooler

Historical review and beginnings of an industrial chiller

Jean Louis Baudelot (1797–1881), was born in France, and studied engineering in Belgium. Though he claimed several inventions, fame came in 1856, when he patented a liquid cooler. Specifically intended for the brewing industry.

A cousin who was a brewer presented him with the fact that until then beer worts had to be cooled in a shallow vessel (cool ship) and stirred during a whole night—a process that easily took 8 hours. Worse, the continuous exposure of the worts to the air resulted often in unwanted inoculation and infected beer. Yet exposure was mandatory because beer yeasts need oxygen at the outset of fermentation. Therefore, the wort needs to be well aerated.

Baudelot envisaged a fine double copper sheet overlaying copper tubes (first cylindrical, later elliptical in cross-section) wherein cold water (spring water or icewater) ran countercurrent to the worts. The worts were collected on top of the cooler in shallow tray, and then finely dispersed, flowing over outside of the copper sheets, which were being being cooled internally. In this way, cooling took place in less than a quarter of the original time needed, limiting exposure to contaminating microbes, while aeration was assured. Hot wort flowed like an undulating waterfall down the exterior of the cooler, emerging cool and aerated at the bottom. It was a massive improvement that led to beer of much better quality and stability.