Hybrid Cooling Systems: Chillers Combined with Heat Exchangers

The Limitations of Industrial Chillers Single System

Although chillers offer excellent temperature control, they may struggle under certain conditions:

• Reduced condenser efficiency in high ambient temperatures
• Poor airflow or confined space installations
• Sudden heat spikes during continuous operations
• No auxiliary cooling available for immediate relief

Why Add a Finned-Tube Heat Exchanger?

Finned tube heat exchanger are high-efficiency heat exchangers that rapidly release heat into ambient air.
When used in tandem with a water chiller system, they bring multiple benefits:

1. Dual cooling paths = better performance
   Chillers regulate fluid temperatures, while air coolers remove excess heat in real time.
2. Reduced load on the chiller = longer lifespan
   Lower operating intensity extends system durability.
3. Fast reaction to heat spikes = better thermal stability
   Air coolers act as an immediate buffer during sudden temperature increases.
4. Energy savings during low-load periods
   Air cooling alone may be sufficient at night or under partial load.

Case Study: Metal Forging Line

A client in the forging industry struggled with rising equipment temperatures every summer.
Their chiller system alone couldn’t stabilize thermal conditions.
Real Tern provided a hybrid cooling solution that integrated a finned air cooler. The outcome:

• More stable production temperature, less thermal distortion
• 20% reduction in chiller operating time
• Noticeable savings in electricity costs during summer

When to Consider Hybrid Cooling:

• High-heat industries: metal, plastic, foundry, welding
• Environments requiring rapid heating/cooling cycles
• Indoor setups with limited ventilation or space
• High-precision industries seeking energy savings & machine longevity

Final Thoughts

Cooling isn’t just about temperature—it’s about protecting your process, your equipment, and your bottom line.
Hybrid cooling systems offer flexibility, resilience, and improved energy performance.
Interested in thermal load assessments or customized cooling designs?

Get in touch with Real Tern—we’re here to build the right solution for your production needs.