How to Choose a Chiller for a Blister Packaging Machine?

Selecting a chiller (industrial chiller/water chiller) to complement a blister packaging machine is a critical decision that directly impacts blister forming quality, production speed, and equipment stability. The chiller provides constant-temperature circulating cooling water to the forming molds and cooling rollers of the blister machine, allowing the thermoformed plastic to cool and solidify quickly.

The following is a systematic selection guide, divided into five core steps:

Step 1: Clarify Core Requirements – Matching the Blister Machine

This is the foundation of the selection process, requiring key parameters from the blister machine itself.

1. Cooling Capacity (Key Parameter):

What it is: The "cooling capacity" of the chiller, usually measured in kW or kcal/h (1 kW ≈ 860 kcal/h). It must be greater than the total heat that the blister machine needs to dissipate during operation.

How to determine:

• Preferred method: Directly consult the blister packaging machine's instruction manual or technical parameter sheet, which usually specifies the minimum cooling capacity required for the chiller. This is the most accurate and reliable data.
• Estimation method: If no specific data is available, consult the blister machine manufacturer or use empirical formulas. Generally, high-speed blister machines (> 30 meters/minute) may require a cooling capacity of 15kW or more, while medium-to-low-speed equipment may require between 5-15kW. Be sure to include a 15-25% safety margin to account for increased ambient temperature or future speed increases.

2. Temperature Control Range and Accuracy:

• Temperature range: Blister forming cooling typically requires water temperatures between 5℃ and 15℃. When selecting a chiller, its stable operating temperature range should cover this range.
• Control accuracy (crucial): Water temperature fluctuations directly affect the uniformity and transparency of blister forming. A model with high temperature stability (±0.5℃ or higher accuracy, such as ±0.1℃) must be selected. The higher the accuracy, the more stable the blister quality.

3. Water Flow Rate and Pressure:

• Match the chiller's rated flow rate (m³/h or L/min) and head (pump pressure) to the requirements of the blister machine's cooling water circuit. Insufficient flow rate and pressure will result in poor cooling performance.

Step 2: Determine the Chiller Type

Select based on site conditions and operating environment:

1. Air-cooled chiller:

• Principle: Dissipates heat into the air through fans and radiators.
• Advantages: Simple installation, no need for additional cooling water source, easy to move, suitable for environments with limited water resources or well-ventilated workshops.
• Disadvantages: Cooling efficiency is significantly affected by ambient temperature; cooling efficiency may decrease during high summer temperatures, and there is some noise and hot air discharge during operation.
• Applicable: The preferred choice for most workshops, especially suitable for small and medium-sized blister packaging machines.

2. Water-cooled chiller:

• Principle: Requires a matching cooling tower to dissipate heat through cooling water circulation.
• Advantages: High cooling efficiency, more stable operation, especially advantageous in high-temperature environments, and relatively low operating noise.
• Disadvantages: Complex installation, requires an additional cooling tower and circulating water system, resulting in higher overall investment and larger footprint.
• Applicable: Large, high-speed blister packaging production lines, or situations where the workshop ambient temperature is extremely high and ventilation is poor.

Step 3: Focus on Key Performance and Configuration

1. Compressor (the heart):

• Brand: Preferably choose internationally renowned brands (such as Copeland, Danfoss, Bitzer) or high-quality domestic brands, ensuring high reliability and low energy consumption.
• Type: Scroll compressors have low noise, high energy efficiency, and simple maintenance, making them an ideal choice for medium and low-temperature chillers.

2. Water pump and water tank:

• Water pump: Choose a high-quality water pump that is corrosion-resistant and has matching flow rate and head. Ideally, there should be a backup pump or adjustable pump power.
• Water tank capacity: The water tank capacity should be sufficient to ensure stable water temperature and system buffering. Too small a capacity will lead to frequent compressor starts and stops.

3. Control system:

• Human-machine interface: A clear digital display screen that can display real-time information such as set temperature, actual temperature, pressure, and fault alarms.
• Control logic: Should have PID intelligent temperature control function to achieve precise and stable temperature regulation.
• Protection functions: Must have multiple safety protections, including high pressure, low pressure, overcurrent, phase loss, anti-freeze, and water shortage alarms.

4. Materials and Water Treatment (Crucial for Blister Packaging Machine Lifespan):

• Evaporator Material: In the pharmaceutical or food industry, it is recommended to use stainless steel (such as 304/316) for parts in contact with cooling water (such as evaporators and pipelines) to prevent rust contamination of the water circuit and the internal cavities of the blister packaging machine molds.
• Water Filtration: Built-in or external filters prevent impurities from clogging the precision cooling channels inside the blister packaging machine.

Step 4: Consider Installation, Service, and Compliance

1. Installation Environment: Measure the dimensions of the installation location to ensure sufficient heat dissipation space (space is needed in front of and behind air-cooled units) and maintenance access.
2. Noise Level: If the workshop has noise requirements, inquire about the operating decibel level of the equipment.
3. Energy Consumption Indicators: Pay attention to the energy efficiency ratio (COP); higher energy efficiency means more power savings in the long run.
4. After-Sales Service: Does the supplier provide installation guidance, warranty period, and timely technical support and spare parts supply?
5. Industry Compliance: If used in the pharmaceutical industry, the equipment design should be easy to clean, the materials should preferably have relevant certifications, and the control system data should ideally be able to output records.

Final Recommendations

1. Prioritize Consultation: First, communicate with your blister packaging machine manufacturer; they usually have recommended brands and models of compatible chillers that have been proven effective.
2. Request Proposals: Provide your blister packaging machine model and production requirements (such as ambient temperature and target water temperature) to 2-3 professional chiller suppliers and request written selection calculations and configuration proposals.
3. On-Site Inspection: If possible, visit a customer site using a similar configuration to understand the actual operating performance.
4. Clarify Budget: After meeting the three core requirements of cooling capacity, temperature accuracy, and materials, then weigh the price and brand.

Remember: A well-matched chiller is the "unsung hero" of a stable blister packaging production line. While its initial investment is relatively small, its impact on product quality and production efficiency is crucial. Do not compromise on this critical component.