As temperatures rise, industrial cooling systems come under increased strain. Without proper preparation, reduced efficiency, higher energy consumption, and unexpected downtime can quickly disrupt production.
After months of wind, rain, leaves and cold weather, your chiller may already be carrying hidden issues. A thorough inspection and clean before the summer months will help ensure reliable performance when demand is at its highest.
Why chillers struggle in hot weather
Chillers rely on ambient air to reject heat. As outdoor temperatures increase, this process becomes less effective, forcing key components such as compressors to work harder to maintain cooling performance.
This additional load can:
- Reduce overall system efficiency
- Increase energy consumption
- Accelerate wear on critical components
- Raise the risk of alarms or system shutdowns
Without preventative maintenance, these issues can escalate quickly during periods of sustained heat.
Warning signs to watch for
Early intervention is key to avoiding costly downtime. Common indicators that your chiller may be underperforming include:
- Frequent alarms or unexpected shutdowns
- Rising operating temperatures or poor cooling performance
- Reduced process efficiency or inconsistent product quality
- Unusual noises or changes in system behaviour
Monitoring these signs closely allows problems to be addressed before they impact production.
The impact on production
When a cooling system struggles, the effects can be felt across the entire operation. Temperature instability can lead to increased defects, higher waste levels and reduced product quality.
Unplanned downtime is another major risk. Even short interruptions can delay production schedules, impact delivery commitments and result in significant financial cost, particularly during peak demand periods.
Chiller maintenance summer checklist
(Note: these steps should only take place when the chiller is stopped and isolated electrically)
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Clear away dirt and debris
Windblown dirt, leaves and other debris can surround the chiller and even get inside the enclosures. Surrounding dirt or debris should be cleared away to ensure good airflow and access to the unit. For a deeper clean to deal with rodents or nests, we advise getting a professional who has undertaken a risk assessment and is aware of all the potential hazards.
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Cleaning coils – dirty coils reduce efficiency
Similar to the previous point, the condenser coils and fins on your chiller should be cleaned properly to ensure effective heat exchange. Dirt build up, makes it harder to transfer heat through the refrigeration process, which forces your chiller to work harder, reducing its cooling capacity and increasing energy consumption and operating costs.
Coils should be inspected and cleaned with suitable approved chemicals and mains water and using a soft hand brush. Using a pressure washer, incorrect cleaning agents and non-suitable brushes could cause damage to your chiller.
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Condenser intake filter
Where an intake filter panel is fitted, it should be removed, examined and cleaned. If dirt builds up, then it will have the same impact as a dirty condenser coil. This is very important for point of use chillers, where the unit is usually located internally, in an oily or dusty environment.
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Clean and inspect panels and steelwork
Wipe down each panel and the chiller frame along with the supporting structure, inspect for corrosion or breach of panel seals. If found, then repair/treat where appropriate to prevent additional damage. Any dirt or mould left on and untreated can quickly become permanent and may become corrosive. Check to make sure there isn’t any water pooling on panels, hinges or around the base of the unit.
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Check for leaks
Water leaks should be self-evident, the piping, pumps and associated components need inspection. Refrigeration and oil leaks are much harder to detect and will need an examination and leak test by a technician. Don’t try to repair the leaks yourself, contact us for an examination and to organise an FGas certified repair scheme.
If fitted, testing any fixed leak detection systems and testing the alarms should be performed.
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System and chilled water
Your chiller is considered to be the heart of the system, however the system that connects to it is just as vital to ensure optimum performance and health. Strainers should be checked for proper flow and pressure, valves and actuators along with flow switches and trace heating should be inspected and tested to make sure simple alarms and potential call outs are avoided. A test of the water viscosity should be performed with a refractometer for frost protection.
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Planned maintenance and servicing
Finally, and most importantly, ensure your chiller has a scheduled service in place. Regular preventative maintenance is the most effective way to maintain efficiency, reduce the risk of breakdowns and extend the lifespan of your system.
Inspection of switchgear, compressors and control systems, alongside the checklist above, will help ensure your chiller is fully prepared for summer demand. Many of these procedures require a qualified engineer, and professional servicing ensures your system continues to operate safely and at optimal performance.
If you’d like support preparing your system for the warmer months, contact our team who can help assess, service and optimise your cooling setup to keep your operation running smoothly.Scarlett O'Connor