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Archives for July 2020

Data Center Cooling

Brooke Loeffler · Jul 21, 2020 ·

Cool Tech

Data centers are the invisible heroes of our modern digital age. Their presence enables our communications, streaming, downloading, research, work, and play 24 hours a day, 365 days a year. As of 2020, there are around 20 Billion devices currently connected to the internet. These centers serve as crucial hubs for data transmission and storage, and they are becoming larger and more advanced every year.

server cooling solutions
Data Center Aisle

For all electronic and mechanical equipment, greater power consumption equals greater thermal output. Therefore the larger the data center, the more waste heat needs to be removed. Overheating servers crash, go off-line, corrupt data, and can damage expensive hardware. Let’s take a look at the specialized world of data center thermal management.

Ideal Server Environment

Ideally, server rooms and data centers should be kept around 72° F with 45% relative humidity. Computer servers can tolerate slightly higher temperatures (up to 90°), but that leaves no room for heat spikes that can occur due to equipment malfunction, or even an exterior door being left open. 

Chilled Inside and Out

Data center cooling begins deep in the heart of the hardware itself. As internal CPU components generate heat, that heat is collected into a heat sink. From there, fans or liquid cooling tubes transfer the heat outside the computer’s case. Once the server’s waste heat is dispelled into the ambient air, it needs to be removed from the data center itself. From here, industrial air chilling units cool the ambient air and expel the waste heat from the building.

Innovative Heat Dispersal

Some tech companies have innovated environmentally safe ways to reuse this heat instead of just dispersing it into the atmosphere. Repurposing heat also helps fight the perception that data centers are heartless energy hogs. Here are just a few examples of how data centers recycle waste heat:

  • Facebook’s data center in Odense, Denmark pipes waste heat to over 7,000 local homes
  • Telecity’s data center in Paris, France heats an onsite arboretum
  • The University of Notre Dame reuses the heat from from their Research Computing Center to heat a greenhouse and botanical garden

Cool Design Features

Data centers are specially engineered for the strategic flow of cool and hot air. By carefully managing layout and exhaust port orientation, data centers can optimize every BTU of cooling power. 

Raised Racks/Floors

Raised floor to assist cooling in a data center

Data centers often house their server racks on double layered raised floors to facilitate cooling. Cables and wiring are run through the negative space between a concrete subfloor and a removable panelled top floor. Not only does this make it easier for technicians to access wires and cables for inspections and repairs, but this also improves airflow throughout the server room. 

Cool air is forced between the floors and can exit through strategically placed perforated tiles. Perforated tiles are placed next to server rack front and allow cool air flow up into the server room. Efficient air flow is critical for data center cooling management. 

Hot and Cold Aisles

To save energy and optimize air flow, data centers organize their server racks to create hot and cold aisles. Server rack fronts are lined up to directly face air conditioning output. Cold air flows through the server racks removing heat and expelling it out the exhaust in the back. Server rack exhausts are lined up to directly face the ac return ducts.

Immersion Cooling

Some data centers have begun experimenting with immersion cooling. This cooling method involves completely submerging server racks into tanks filled with dielectric liquid or oil. Dielectric fluids are specialized non-conductive liquids through which no electric current can pass. They can electronically insulate even high voltage equipment and prevent arcing. When this fluid is chilled, it also acts as a liquid coolant for the running servers. 

North Slope Chillers Data Center Cooling Solutions

Redesigning server room layouts is expensive and creates problematic downtime. North Slope Chillers is proud to offer powerful portable server room chilling that is easy to install without altering your current system. With a wide range of cooling capacities, we can provide you with the exact temperatures you need to continuously keep your servers running cool. Contact us to find the right server room cooling solution for your needs at (866) 826-2993 or [email protected]

Portable Chillers For Injection Molding

Brooke Loeffler · Jul 14, 2020 ·

Plastic Injection Molding

Plastic injection molding is a crucial manufacturing process in today’s modern world. The ability to mass produce identical plastic components further drives innovation and industrial progress every year. The goals of successful plastic manufacturing are precision, repeatability, and speed. These same goals should be applied to cooling plastic as well.

The cooling process can consume at least 80% of the overall plastic manufacturing time. That means, by applying an efficient industrial cooler to the injection molding process, you can greatly reduce the amount of time spent on each batch. But where does one begin the process of looking for an injection molding chiller? Let’s take a closer look.

Learn more about Plastic Injection Molding
Plastic pellets

What to Know When Selecting an Injection Molding Chiller

Cooling molten plastic is a complex science with many variables. However, there are certain questions that will guide you when selecting an injection molding chiller.

What are my melting points?

Plastic melting temperatures vary greatly depending upon the type of plastic required for the job. Knowing the molten temperature of your plastic in the nozzle is the first step in selecting a chiller that will cool it before ejection. Here are some common plastic melting points and ranges:

North Slope Chillers graphic on the melting points of common injection molding plastics
  • Polypropylene (PP): 320° F (160° C)
  • Low Density Polyethylene (LDPE): 356-464° F (180-240° C)
  • High Density Polyethylene (HDPE): 410-518° F (210-270° C)
  • Acrylonitrile Butadiene Styrene (ABS): 374- 518° F (190-270° C)
  • High Impact Polystyrene (HIPS): 356-518° F (180 – 270° C)
  • General Purpose Polystyrene (GPPS): 338-536° F (170-280° C)
  • Polyoxymethylene: (POM): 347° F (175° C)
  • Acetal: 356-410° F (180-210° C)
  • Acrylic: 428-482° F (220-250° C)
  • Thermoplastic Polyurethane (TPU): 374-428° F (190-220° C)
  • Polycarbonate: 550° F (287° C)

These melting points and ranges may vary depending upon the plastic manufacturer. Be sure to thoroughly research your plastic’s heating needs so you know what your goal temperatures are.

What are my HDTs?

Next, research the Heat Distortion Temperature (HDT) of your plastic selection. Plastic components need to be chilled below their HDT in order to avoid deformation when ejected from the mold. HDTs differ depending upon the plastic’s composition, the molten density, and the pressure in the mold. Again, consult your plastics manufacturer to ensure you know your chosen material’s temperature ranges.

What is my desired mold temperature?

Proper plastic chilling is more involved than just cooling as quickly as possible…it involves carefully hitting temperature targets. Your plastic manufacturer will also be able to provide the ideal mold temperature for your plastic selection. Achieving your mold temperature allows your plastics to cool and crystallize properly in the mold. Proper crystallization prevents cavity formation, stress cracking, creeping and seeping plastic, and other deformities.

How much space do I have?

Injection molding equipment can take up a large amount of space on the factory floor. Because chilling equipment can greatly add to that footprint, you will need to know how much room you have to work with. Water cooled chillers use a cooling tower that takes up more space than air cooled chillers, so select an industrial chiller that will meet your space requirements.

How much cooling power do I need?

Chiller sizes are traditionally listed according to “tons.” Tons does not refer to the actual weight of the chiller, but instead is a historical reference to a time when blocks of ice were harvested for cooling. Just like engines are still measured according to “horsepower”, the term “tons of refrigeration” stuck around. 1 ton of cooling power = 12,000 btus per hour. 

Cooling power for your injection mold

North Slope Chiller graphic on injection mold cooling

As a general rule of thumb, 1 ton of cooling power is sufficient to cool the following flow rates of molten plastics to a safe ejection temperature:

  • 30 lbs/hour of HDPE
  • 35 lbs/hour of LDPE
  • 35 lbs/hour of PP
  • 50 lbs/hour of HIPS and GPPS
  • 50 lbs/hour of ABS
  • 65 lbs/hour of Polycarbonate

Cooling power for additional equipment

In most cases, the injection mold will not be the only piece of equipment in need of cooling. There are other pieces of auxiliary equipment that require process cooling in order to extend your machine’s duty cycle.

  • Hydraulic motor (additional .1 tons of cooling per horsepower)
  • Feed Throat (additional .5 tons of cooling)
  • Thermolator (additional .2 ton per pump horsepower)
  • Hot Runners (additional .15 ton cooling per kilowatt hour)
  • Dryer Aftercooler (consult your dryer manufacturer to determine how much additional cooling is required)

What Should An Injection Molding Chiller Have?

Portability

Portable industrial chillers give you a greater amount of flexibility and save valuable floor space.

Quiet Compressors

Anytime you install additional equipment on an injection mold factory floor, you increase the operational noise in your facility. Your chilling unit should be powered by compressors that operate efficiently but quietly. In general, chillers with reciprocating compressors are much louder than centrifugal, scroll, or screw compressors.

Flexible Temperature Ranges

The plastic cooling process will vary depending upon many factors: size and thickness of the plastic part being made, type of plastic, etc. Installing an industrial chiller with the flexibility to hit a range of temperatures broadens your manufacturing capabilities. 

Recirculation

Save money and protect our precious resources by installing a recirculating chiller. Recirculation greatly reduces water consumption and will help you save on utility bills in the future.

Precise Temperature Controls

Molten plastic can behave in unpredictable ways unless you hit precise temperature targets during the heating and cooling process. Smart thermostatic controllers give you peace of mind with greater access to cooling time frames and temperature ranges.

Customization

Some injection molding operations require specific components and specifications to meet their cooling needs.

For example, plastic products made for the food and beverage, bio and pharmaceutical, industries must meet FDA standards for food-grade materials. Facilities that manufacture these plastics must maintain clean-room conditions and all equipment must be easy to wipe down and sanitize. Injection mold chillers for these facilities should contain corrosion resistant components. They should also be contained inside easy-to-clean enclosures to help maintain factory cleanliness.

Efficient Cooling Fluids

Injection mold chillers must produce cooling power that is able to penetrate through the mold and efficiently remove heat from the plastic. Fluids such as water/glycol mixes remove waste heat more efficiently than water alone.

North Slope Chillers Injection Mold Chilling Solutions

North Slope Chiller graphic on injection mold cooling solutions

At North Slope Chillers, we are proud to offer portable and powerful injection mold chilling solutions. Easy to install and use, our chillers come with a wide range of cooling temperatures. In addition, our customization process is the fastest on the market and can provide you with the exact specifications you require.

Contact us to find the right injection mold cooling solution for your needs:

(866) 826-2993 [email protected]

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Salt Lake City, UT 84104
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Email: [email protected]

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