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Improve Efficiency and Product Quality The Power of OUMAL Industrial Chillers

2025-08-08

In today’s fast-paced manufacturing industry, companies are constantly looking for ways to increase efficiency, reduce costs and improve product quality. The choice of industrial cooling equipment is a critical factor in achieving these goals, but it is often overlooked. OUMAL Refrigeration Machinery Co., Ltd. leads the way in this field with its development and manufacture of innovative heat transfer products, such as 30 ton air-cooled chillers and 20 ton air-cooled chillers, designed to meet the unique cooling needs of a wide range of industries around the world.


Improve Efficiency with Cooling Solutions from OUMAL

OUMAL understands the needs of industries such as injection molding, thermoforming, blow molding, blown film production, plastic extrusion and compounding. For each application, the right cooling system is critical. By providing energy-efficient process cooling, OUMAL’s chillers not only ensure optimal temperatures, but also improve product quality and reduce production time. Whether you are producing high-quality plastic parts or ensuring a stable mix of composite materials, OUMAL’s chillers provide reliable and precise support for your production process.


Customized Solutions for Every Need

Flexibility is at the heart of OUMAL’s mission. OUMAL focuses on customer satisfaction and offers a wide range of customization options, and its 30 ton air-cooled chiller and 20 ton air-cooled chiller are just the beginning. OUMAL’s manufacturing facility is fully equipped to produce high-quality products and offers a wide range of modifications and options. Whether you need a system with unique specifications or a modification to your specific application, OUMAL has you covered.


In addition to improving productivity, OUMAL chillers are designed with energy efficiency in mind. With energy costs rising, investing in a high-quality, energy-efficient chiller is a smart move for long-term profitability. OUMAL’s products help companies reduce operating costs while maintaining the high performance required for critical industrial applications.

industrial cooling solution


OUMAL’s commitment to innovation, customer-centric solutions and flexibility sets it apart in the industry. Over the years, their sales and application support teams have developed a deep understanding of the needs of a wide range of industries and can provide expert advice for almost any application. Whether you want to optimize your injection molding process or increase the efficiency of thermoforming, the OUMAL team is ready to recommend the most suitable chiller to meet your needs.


When it comes to industrial cooling solutions, OUMAL Refrigeration Machinery Co., Ltd. is your trusted and innovative partner. Its Air-Cooled Chillers series, including 30 ton Air-Cooled Chillers and 20 ton Air-Cooled Chillers, provide the efficiency, customization, and performance you need to take your business to the next level. With OUMAL, you are investing in more than just a product, but a solution that can shorten production time, reduce costs, and improve the overall quality of your products.


Choose OUMAL as your next industrial cooling solution and experience the difference that innovative, energy-saving technology can make.


Troubleshooting Water Cooled Screw Chillers Common Faults and Fixes

2025-08-08

Troubleshooting Water Cooled Screw Chillers: Common Faults and Fixes

You might have high-pressure trips, refrigerant leaks, or compressor overload when using a water cooled screw chiller. Fast troubleshooting helps lower downtime and expensive repairs. Regular checks and preventive maintenance help find problems early. Knowing your water cooled chiller well helps you see issues before they get worse.


Water Cooled Screw Chiller Faults

140 HP Water Cooled Screw Chiller

  • High Pressure

High pressure alarms can happen in your water cooled screw chiller. Air or other gases in the system can cause this. Too much refrigerant or a dirty condenser can also be the reason. If the cooling water is too warm, pressure goes up fast. Low water flow makes pressure rise too. Dirt in pipes or a broken water pump can cause high pressure faults. To fix these, clean the condenser and check water flow. Adjust the refrigerant level if needed.

Tip:If you see high pressure, always look for dirt on the condenser surface.

  • Low Pressure

Low pressure is another problem you might see. This can happen if there is not enough refrigerant or if there is a leak. Cold weather can make water and oil colder, causing low pressure alarms. Blocked filters or pipes can also lead to this. A bad expansion valve or electrical relay can be the cause too. Check for leaks and clean the filters. Make sure all valves are working right.

  • Water Flow Loss

Water flow loss is a common fault in water cooled chillers. This happens if the water pump stops or pipes get blocked. Air in the system can also cause it. Low water flow can make the chiller shut down or work poorly. Always check pumps and pipes for blockages or leaks.

  • Refrigerant Leaks

Refrigerant leaks are serious in water cooled screw chillers. Leaks make cooling worse and use more energy. Some refrigerants can hurt the environment if they escape. Check for leaks often and fix them fast. This helps avoid high costs and protects the environment.

  • Oil System Issues

Oil system issues can harm your chiller. Oil leaks, dirty oil, low oil pressure, or hot oil are common faults. These problems lower lubrication and can make the compressor overheat or wear out. Check oil levels often and change oil when needed. Clean or replace oil filters as well.

  • Electrical Problems

Electrical problems often cause chiller faults. Loose wires, bad relays, or blown fuses can stop the chiller. If your chiller will not start, check the electrical panel first. Make sure all wires are tight and replace any broken parts.

  • Noise and Vibration

Strange noises or vibration can mean mechanical problems. Loose screws, unbalanced fans, or pipes not fixed well can cause rattling or banging. If you hear loud or repeating noises, look for loose parts or debris. Finding these problems early helps stop bigger faults and keeps your chiller working well.


Fault Type

Common Causes of Chiller Problems

Quick Fixes

High Pressure

Dirty condenser, low water flow, air

Clean condenser, check water flow

Low Pressure

Leaks, blockages, cold water

Fix leaks, clean filters

Water Flow Loss

Pump failure, pipe blockage

Inspect pumps, clear blockages

Refrigerant Leaks

Damaged pipes, loose fittings

Repair leaks, recharge refrigerant

Oil System Issues

Low oil, dirty oil, leaks

Change oil, fix leaks

Electrical Problems

Loose wires, bad relays, blown fuses

Tighten wires, replace parts

Noise and Vibration

Loose parts, unbalanced fans, bad mounts

Tighten, balance, secure parts


Chiller Troubleshooting Steps



Troubleshoot Pressure Issues

Pressure problems in your chiller can cause shutdowns or poor cooling. You can follow these steps to find and fix pressure faults:

  1. Check all valves. Make sure refrigerant valves are open. Isolation valves should stay closed unless you need them for repairs.

  2. Look at the water flow. The water pumps must run well. Both the condenser and evaporator need enough water flow to keep the chiller cool.

  3. Inspect the condenser coils. Dirt or debris can block heat transfer and raise pressure.

  4. Watch the condenser fan. The fan should spin in the right direction and work without stopping.

  5. Use the chiller manual. Find alarm codes and follow the troubleshooting methods listed.

  6. If you see high pressure alarms, check for air or non-condensable gases in the system.

  7. Ask a qualified technician to test high pressure switches, contactors, and relays if you cannot find the problem.

Tip:Clean the condenser coils often. This simple step prevents many pressure issues.


Troubleshoot Water Flow

Water flow problems can stop your chiller or make it noisy. Use these troubleshooting methods to restore proper flow:

  1. Read all safety instructions before you start.

  2. Unplug the chiller and drain the water. Remove hoses and tilt the unit to empty it.

  3. Take out the cartridge filter. Soak it in water for two minutes, then put it back.

  4. Check every hose and fitting for air leaks. Use Teflon tape and tighten clamps to stop air from getting in.

  5. Prime the system. Disconnect the water inlet hose, lift it up, and pour water until no bubbles come out of the outlet.

  6. Start the chiller for one minute. Watch for steady water flow and no bubbles. Repeat priming if needed.

  7. You can flush the system with a garden hose to clear air pockets.


Problem

Possible Cause

Recommended Solution

Low water flow

Dirty or clogged filter

Clean or replace the filter

Low water flow

Air lock

Repeat priming steps

Chiller making noise

Air in water line

Check hoses and prime again

Note:Always keep the water level above the inlet and outlet ports. Clean filters and pipes often to avoid clogs.


Troubleshoot Refrigerant Problems

Refrigerant faults can cause poor cooling or strange noises. Follow these troubleshooting methods to find the cause:

  1. Watch for signs like weak cooling, ice on coils, or odd sounds.

  2. Look for leaks or airflow problems around the chiller.

  3. Use manifold gauges to check refrigerant pressures.

  4. Test for leaks with an electronic detector or UV dye.

  5. Inspect the expansion valve for blockages. Make sure superheat settings are correct.

  6. Check the evaporator coil for dirt or ice. Good airflow is important.

  7. Look at the filter drier and pipes for restrictions.

  8. Measure suction and discharge pressures at the compressor. Listen for odd noises.

  9. Check sensor readings. Replace or calibrate sensors if they are wrong.

  10. Do regular maintenance. Clean coils and filters, and check for leaks often.

Safety Alert:Always use the right recovery cylinder for each refrigerant type. Never overfill cylinders. Use EPA-certified tools and keep records of all refrigerant handling.


Troubleshoot Electrical Issues

If your chiller cannot start or stops working, electrical faults may be the cause. Try these troubleshooting methods:

  • Open the electrical panel and look for loose wires or burned parts.

  • Check all relays, fuses, and contactors. Replace any that look damaged.

  • Make sure the power supply is correct and all phases are connected.

  • Use a multimeter to test voltage and current at key points.

  • If you find a problem you cannot fix, call a licensed electrician.

Tip:Always close the electrical panel after checks to keep dust and moisture out.


Troubleshoot Noise and Vibration

Strange noises or shaking can mean loose or broken parts. Use these steps to troubleshoot:

  • Listen for rattling, banging, or humming sounds.

  • Check all screws, bolts, and mounts. Tighten any that are loose.

  • Inspect fans and pumps for balance. Replace or repair if needed.

  • Look at pipes and hoses. Secure them to stop vibration.

  • If noise continues, ask a technician to check for deeper mechanical issues.


Chiller Troubleshooting Checklist

You can use this checklist for quick chiller troubleshooting. It helps you spot problems early and decide when to call a professional.

  1. Inspect the mechanical room. Keep it clean and safe.

  2. Check the electrical panel. Make sure it is closed and dry.

  3. Look at all pipes for leaks or corrosion.

  4. Read temperature gauges. Compare setpoint, return, supply, and condenser water temperatures.

  5. Watch the chiller run. It should not short cycle or make loud noises.

  6. Test water quality. Look for rust or scale.

  7. Check oil pressure and temperature. Look for oil leaks.

  8. Make sure all wiring is tight and fuses are good.

  9. Use the chiller’s fault codes and self-diagnosis features.

  10. If you find leaks, slow cooling, or loud noise that you cannot fix, call a professional.

Remember:Regular chiller troubleshooting and maintenance keep your water cooled screw chiller running longer and more efficiently.

You can keep your chiller working well with regular care.

  • Cleaning filters and checking water flow help stop chiller problems.

  • Checking fan motors and sensors often helps avoid big repairs.

  • Running tests makes sure your chiller works well.


Maintenance Activity

Approximate Cost

Energy/Operational Savings

Tube Cleaning

$5,000

Saves more than $15,000 on energy each year

Compressor Overhaul

$20,000

Stops $50,000 in lost work time

Taking care of your chiller saves money and helps it last longer. Always use the troubleshooting checklist when you find a problem. If you cannot fix the chiller, call an expert. Regular care and checks help protect your chiller.


What Sets 10 HP Process Chillers Apart for Industrial Metal Finishing

2025-08-08

10 HP process chillers are special in metal finishing. They give very accurate temperature control and work well every time. Good chillers help keep metal finishing steady. This stops cracks, warping, and other problems. Studies show that controlling temperature makes metal harder and stronger. It also helps the metal bend without breaking. It uses less energy and saves money too. A good industrial process chiller keeps the workplace the same all the time. This makes every finished product better and more exact. Companies use these chillers for tough jobs and to work fast.


Energy-efficient Process Chillers

Key Takeaways

  • 10 HP process chillers keep metal finishing cool and steady. This stops cracks, warping, and weak metal from happening. These chillers have strong parts like stainless steel tanks and copper coils. These parts help them last a long time and work well. Microcomputer controls keep the temperature just right. This makes products better and saves energy. They do not need much maintenance. They have safety features to protect machines and stop breakdowns. 10 HP chillers are flexible and save energy. They are easy to move and good for many metal finishing jobs.


10 HP Chiller Features

A process chiller is a machine that cools things down in factories. The OUMAL OMC-10A 10 HP chiller is great for metal finishing. It uses air-to-water cooling and has a copper coil that is strong. The tank is made of stainless steel, so it does not rust and keeps water clean. Workers can use the microcomputer control panel to set and check the temperature. This chiller keeps the temperature steady, which is very important for metal finishing.

Note: The OMC-10A model uses good parts like Schneider electrical components. These parts help the chiller stay safe and work well.

The table below lists the main features of 10 HP process chillers used for metal finishing:

Feature Category

Details / Examples

Compressor

Air-cooled scroll compressors (Copeland, Panasonic)

Refrigerants

R22, R407C, R134A, R404A

Heat Exchanger / Tank

Stainless steel water tanks, shell and tube heat exchangers

Water Pump

Durable, corrosion-resistant pumps

Electrical Components

Schneider for stability and safety

Safety Devices

Overheat, high/low pressure, phase protection, anti-freeze

Condenser Type

Air-cooled finned condensers

Temperature Control

Microcomputer control, precise regulation

Portability

Casters for mobility

Copper coils and stainless steel tanks help the chiller last a long time. These materials stop rust and keep the chiller working well. The OMC-10A chiller can cool with 27 kW (7.7 tons), which fits many metal finishing jobs. It uses about 9.2 kW of power, so it is good for saving energy and cooling.


Bar chart comparing cooling capacity and input power for OUMAL OMC series chillers

How Process Chillers Work

Process chillers use a simple cycle to cool things down. First, the refrigerant goes into the evaporator. It takes heat from the process fluid, like the liquid used in metal finishing. The refrigerant turns into a gas. The compressor pushes this gas to a higher pressure and temperature. Then, the gas goes to the condenser. In air-cooled chillers, the condenser lets out the heat into the air, and the gas turns back into a liquid. The liquid goes through an expansion valve, which makes it cooler and lowers the pressure. The cycle starts again.

  1. The refrigerant takes heat from the process fluid in the evaporator.

  2. The compressor makes the refrigerant gas hotter and under more pressure.

  3. The condenser lets out heat to the air, turning the gas into a liquid.

  4. The expansion valve cools the liquid, and the cycle repeats.

Microcomputer controls help keep the temperature steady. They let the chiller keep the water temperature close to the same, usually within ±1°C. This is important for process chillers in metal finishing. The OMC-10A chiller uses these controls to keep things safe and make sure the results are good.


Metal Finishing Cooling Needs

Metal Finishing Cooling Needs

Temperature Control Challenges

Keeping things cool is very important in metal finishing. Jobs like anodizing, plating, and quenching need steady temperatures. If the temperature changes a lot, metal can bend or break. It might also get weaker. Workers have some problems when they try to keep the right temperature:

  • Some materials, like plastics or MDF panels, can bubble or crack if they get too hot.

  • Certain parts must stay within a set temperature. If it gets too hot, these parts can bend or break.

  • Some parts, like refrigerant compressors, need careful heating and cooling.

  • Metal parts with different thicknesses can heat up unevenly. This makes it hard to keep the whole part at the right temperature.

  • Big, heavy parts need more heat to process. This can slow down work and cost more money.

A chiller helps by keeping the temperature steady. The 10 HP chiller uses sensors to check for temperature changes during busy times. If the temperature goes up, the chiller sends coolant through heat exchangers to cool things down. When the temperature is right, the system stops sending coolant. This automatic control keeps everything safe and working well.


Application Examples

Keeping the temperature steady helps protect products and machines. Here are some ways bad temperature control can hurt metal finishing:

  1. If the temperature changes, metal can get bigger or smaller. This can cause size mistakes.

  2. High heat can change the metal’s surface or inside. The metal can get softer or weaker.

  3. Too much heat can burn or discolor the metal. It can also cause other surface problems.

  4. Hot conditions can wear out tools faster. Grinding wheels can get damaged too.

  5. Bad temperature control can leave stress in the metal. This can make it bend or break later.

A 10 HP chiller gives the cooling needed to stop these problems. By keeping the temperature in a small range, the chiller helps each job go well. This means better products, less stopping, and longer machine life. Good chillers also help make more products. They help every finished product meet high standards.


Benefits of 10 HP Chillers

Benefits of 10 HP Chillers

Efficiency and Reliability

10 HP chillers save energy and work well in metal finishing. They have special compressors that change speed when needed. This helps keep the temperature steady and uses less energy. Many factories say their energy use drops a lot after using these chillers. The system now uses only about one-third of the energy older chillers used. The pumps also use less power, so more energy is saved.

Factories have fewer problems because the chiller keeps water temperature and pressure steady. This helps protect machines and makes products better.

Chillers with variable-speed compressors do not turn on and off too quickly. This means less stress on the compressor and it lasts longer. Electronic safety features help stop problems before they happen. Soft-start controls help the system start gently and protect the parts. These things make the chiller good for busy factories.

These chillers are small and fit well in crowded places. Wheels make it easy to move them around. The system uses closed water loops, so the water stays clean and needs less care.


Key reliability features include:

  • Steady temperature for better results

  • Fewer breakdowns because of safety features

  • Less waiting because setup is fast and easy

  • Energy-saving choices that cost less to run


Low Maintenance

10 HP chillers need less care than old ones. Most need a check-up once a year. This means checking oil, cleaning coils, and looking at wires. Trained workers should look for leaks and test safety parts. You do not need to change the oil often, but checking it helps keep the compressor healthy.

Typical maintenance steps:

  1. Do all weekly and monthly checks during the yearly service.

  2. Check the oil for water and acid.

  3. Look at and tighten all wires.

  4. Clean and paint any rusty spots.

  5. Clean air filters and coils.

New chillers use safe refrigerants that last longer. Better motors and coils help stop breakdowns. Chillers that are the right size do not have as many problems. This means less fixing and less time when the chiller is not working.

Many factories say they spend 80% less time on maintenance with new chillers. They also need outside help much less. Having spare parts and regular checks helps stop long waits for repairs.

Safety features keep the chiller and factory safe. Some of these are:

  • Protection from too much electric current

  • Switches for high and low pressure

  • Timers for safety delays

  • Power phase protection

  • Anti-freeze protection

These features help the chiller work well and stop big problems. This means the system is efficient, works well, and lasts a long time for metal finishing.


Industrial Process Chiller Comparison

Industrial Process Chiller Comparison

10 HP vs. Other Capacities

Picking the right process chiller depends on what the factory needs. A 10 HP chiller gives good cooling and saves energy. Smaller chillers, like 3 HP or 5 HP, are for easy jobs or small tanks. They use less power but can’t cool big jobs. Bigger chillers, like 20 HP or 30 HP, cool more and fit large factories. These are best when many machines run at once.

A 10 HP chiller is good for medium or big metal finishing work. It cools enough for jobs like anodizing, plating, and quenching. This size works well without wasting energy. Many companies pick 10 HP chillers because they are flexible. They can cool more than one machine or tank at the same time. This makes them a smart pick for businesses that want to grow.

Tip: You can change some parts to fit your job. Pick different refrigerants, evaporators, or power supplies. Stainless steel tanks and pumps stop rust and last longer. Touch screens and safety features make it easy and safe to use.


Air to Water vs. Other Types

Factories can choose air-to-water, air-to-air, or water-to-water chillers. Each type works best for certain jobs. The table below shows how air-cooled and water-cooled chillers are different:

Feature

Air-Cooled (Air-to-Air)

Water-Cooled (Water-to-Water)

Cooling Power

Lower, changes with air temp

Higher, steady in all weather

Energy Efficiency

0.8–1.2 kW/ton

0.45–0.64 kW/ton

Lifespan

15–20 years

20–30 years

Maintenance

Easy, not needed often

Needs water checks, more work

Installation

Small, easy to move

Needs cooling tower, more space

Performance

Drops in hot weather

Stays strong in high heat

Air-to-water chillers use air around them to cool down. They are simple to set up and move. These chillers work best in places that are not too hot. Water-cooled chillers use water from a cooling tower. They cool better and save more energy, even when it is hot outside. Their cooling stays the same even if the weather gets warmer.

Factories can add special features to chillers for their needs. Some options are titanium tube evaporators, very low temperature settings, and smart controls. These help the chiller work for any metal finishing job and keep the system running well.


10 HP process chillers are special in metal finishing for many reasons.

  • They use scroll compressors and eco-friendly refrigerants to save energy. These parts also help the environment.

  • The air-cooled design uses aluminum fin condensers. This gives strong cooling and does not need extra water systems.

  • Stainless steel tanks and good temperature controls keep things safe and steady.

  • These chillers work for many jobs, like anodizing and die casting. They are easy to set up and do not need much care.

Experts say it is best to pick chillers that fit your cooling needs. They should have good parts and strong support after you buy them. Companies that choose the right chiller get better products. Their machines last longer and work better.


FAQ

What makes a 10 HP process chiller ideal for metal finishing?

A 10 HP process chiller gives strong cooling for metal finishing. It keeps the temperature steady so metal does not get ruined. This helps stop mistakes and keeps machines safe. Many factories pick this size because it is powerful and saves energy.

How does the OUMAL OMC-10A chiller ensure temperature stability?

The OUMAL OMC-10A has a microcomputer control panel. This panel checks the temperature and changes it fast. It keeps the water temperature close to the same, between ±0.5°C and ±2°C.

Can a 10 HP chiller handle multiple metal finishing machines?

A 10 HP chiller can cool more than one machine or tank. Its strong cooling helps with many metal finishing jobs. Many companies use one chiller for several tasks at once.

What safety features do 10 HP process chillers include?

These chillers have safety features to stop problems. They protect the compressor from getting too hot. They also have over-current and phase protection. These features help keep the chiller safe and working well.

Are 10 HP process chillers easy to move and install?

Most 10 HP chillers are small and have wheels. Workers can move them without trouble. The setup is easy, so it does not take long to install.


Which Is Better for Your Facility Water Cooled Screw Chiller or Air Cooled Chiller

2025-08-08

Which Is Better for Your Facility Water Cooled Screw Chiller or Air Cooled Chiller


You usually pick a water cooled screw chiller for big places or places that need to be quiet. Air cooled chillers are good for smaller places, places with little space, or where there is not much water.


Factor

Water Cooled Screw Chiller

Air Cooled Chiller

Efficiency

High

Moderate

Cost

Higher

Lower

Maintenance

More

Less

Climate Suitability

Any climate

Mild climates

Space

Needs mechanical room

Needs outdoor space

Noise

Quiet

Louder

Lifespan

Long

Shorter

Every place is different. Think about your space, money, and weather before you choose.


Key Takeaways

  • Water cooled screw chillers use less energy. They are quieter and last longer. These chillers work well in big buildings. They are good for places that are very hot.

  • Air cooled chillers cost less at first. They do not need much care. They fit in small spaces. They are good where there is not much water. But they are louder. They do not work as well in hot weather.

  • Pick your chiller by looking at your building size. Think about the weather and how much water you have. Also, check your budget. This helps you get the best cooling and save money.


How They Work

Water Cooled Screw Type Integrated Chiller machine

Water Cooled Screw Chiller

A water cooled screw chiller gives strong cooling for big places. It takes heat from your building and puts it into water. The water goes through pipes to a cooling tower. The cooling tower lets the heat out into the air. You find these chillers in hospitals, factories, and big offices. They are good for places that need a lot of cooling. Groups like ASHRAE 90.1 and ARI say these chillers work well for big jobs and save energy. New models use special drives and better refrigerants. This helps save more energy and follow strict rules.


Air Cooled Chiller

An air cooled chiller is good if you want something simple. It uses fans to blow air over coils to cool the refrigerant. The heat goes straight into the outside air. You do not need a cooling tower or extra water. These chillers are good for small buildings or places with little water. They are easier to put in and take care of. But they might use more energy, especially when it is hot outside.


Main Differences

The biggest difference is how each system gets rid of heat. Water cooled screw chillers use water and cooling towers. Air cooled chillers use air and fans.


Here is a quick look at how they work:

Metric / Parameter

Water Cooled (Underground Heat Exchanger)

Air Cooled / Conventional Systems

Energy Consumption Reduction

14% less than water-cooled with cooling tower

Baseline (uses more energy)

Water Consumption

No water used (0 m³/m²/day)

About 1.95 m³/m²/day water used

COP Increase

6% to 18% higher in ground source heat pump systems

Baseline COP

Heat Transfer Enhancement

Up to 1.5 times better

Baseline heat transfer

A water cooled screw chiller gives better efficiency and heat transfer. Air cooled chillers are easier to set up and cost less at first. But they may not work as well in big or busy places.


Comparison Factors


Energy Efficiency

You want to use less energy and save money. Water cooled screw chillers are usually more efficient. They use water to move heat, which works better than air. Studies show that if you run chillers together in a smart way, you can cool up to 93 kW more each hour. This saves a lot of energy over time. In big buildings, smart controls help cut energy use by over 11%. They also make the Coefficient of Performance (COP) go up by more than 21%. This means your system does more work for each unit of electricity. Air cooled chillers can save energy too if they have variable-speed fans and smart controls. But they are not as efficient as water cooled chillers, especially when it is hot outside.


Costs

You need to think about both the starting cost and the cost to keep it running. Water cooled screw chillers cost more to put in. You need a cooling tower, pumps, and extra pipes. The base cost is about $1,000 for each ton of cooling. Air cooled chillers cost less to install because they do not need extra water systems. But they may use more electricity, especially in hot or dry places. Here is a quick look at cost factors:

Parameter

Water Cooled Screw Chiller

Air Cooled Chiller

Installation Cost

Higher (cooling tower, piping)

Lower (no cooling tower needed)

Operating Cost

Lower (better efficiency)

Higher (less efficient in heat)

Water Use

High

None

Maintenance Cost

Higher (more parts to service)

Lower (simpler system)

In places with little water or very hot weather, cooling costs can go up by 60%. You might also pay more for water in some areas.


Maintenance

You want a system that is easy to take care of. Water cooled screw chillers need more work. You have to check the cooling tower and clean the pipes. You also need to watch for scale or rust. These systems have more moving parts. Air cooled chillers are simpler. You just clean the coils and check the fans. This means less downtime and fewer repairs. If you want less work, air cooled chillers are easier to handle.


Capacity

If your building needs a lot of cooling, water cooled screw chillers are better. They can handle big loads and work well in hospitals, factories, or tall office buildings. They can run for long hours without losing power. Air cooled chillers are good for smaller buildings or places that do not need as much cooling. They may not work as well if you try to cool a big space or run them all day.


Climate Suitability

The weather where you live matters. Water cooled screw chillers work well in any climate, even if it is hot or humid. They do not lose much efficiency when it gets hot outside. Air cooled chillers work best in places that are not too hot. When it is hot, they use more electricity and do not cool as well. Studies show that in Mediterranean climates, smart fan controls can save up to 12% on electricity. In subtropical areas, advanced controls help air cooled chillers save energy. But water cooled chillers still work better in high heat.

Chiller Type

Best Climate

Key Performance Notes

Water cooled screw chiller

Any (hot, humid, dry)

Keeps high efficiency in all conditions

Air cooled chiller

Mild, not too hot

Efficiency drops in high heat; best with smart controls


Space and Noise

You need to plan where to put your chiller. Water cooled screw chillers need a mechanical room and space for a cooling tower. They run quietly, which is good for hospitals or offices where noise matters. Air cooled chillers go outside. They need open space and make more noise because of their fans and compressors. If you do not have much indoor space or do not mind noise, air cooled chillers may work for you.


Lifespan

You want your chiller to last a long time. Water cooled screw chillers usually last longer—often 20 to 30 years—if you take care of them. Their parts wear out slowly because they run in steady conditions. Air cooled chillers last about 15 to 20 years. Weather and temperature changes can make them wear out faster.

If you want a quiet, long-lasting, and efficient system for a big building, water cooled screw chillers are often best. For smaller spaces or places with little water, air cooled chillers are simpler and cost less.


Pros and Cons

Water Cooled Screw Chiller

A water cooled screw chiller gives strong cooling. It works well for big buildings or places needing steady cooling. This system saves energy, so you pay less over time. These chillers are quiet, so they fit in hospitals, hotels, or offices where noise is a problem. If you take care of it, it will last longer.

Tip: You must have a mechanical room and a cooling tower. Make sure you have enough space and water for this system.

Pros:

  • High energy efficiency

  • Quiet operation

  • Handles large cooling loads

  • Long lifespan

Cons:

  • Higher installation cost

  • Needs regular maintenance

  • Requires water and extra space


Air Cooled Chiller

Pick an air cooled chiller if you want something simple. This system does not need a cooling tower or much indoor space. You can put it outside, so you save room inside. You spend less money to install and take care of it. This chiller is best for small buildings or places with little water.

Note: Air cooled chillers can be loud. They may not cool well when it is very hot.

Pros:

  • Lower upfront cost

  • Simple installation

  • Less maintenance

  • No water needed

Cons:

  • Louder operation

  • Lower energy efficiency

  • Shorter lifespan

  • Not ideal for large cooling needs


Decision Guide

Facility Size

You need to pick a chiller that fits your building. Big buildings, like data centers or factories, need more cooling. Small offices or stores do not need as much. You can use cooling load numbers to help you choose:

Facility Type

Cooling Load Benchmark (ft² per refrigeration tonne)

Data Rooms

80 - 100

Clean Rooms

100 - 300

If your building is large or needs lots of cooling, think about a water cooled screw chiller. These chillers work well for big jobs and save energy when running hard. For small spaces, an air cooled chiller is usually better and cheaper to run.

Tip: Chillers work best at 40-60% of their top power. If your chiller is too big or too small, you waste energy and money.


Climate and Water

Where you live and how much water you have matter a lot. Hot weather makes chillers work harder. Humid air means you need more cooling. If you live where it is hot or humid, a water cooled screw chiller keeps working well. In dry places or where water is hard to get, air cooled chillers or adiabatic cooling systems use up to 90% less water than old cooling towers.

  • Ambient temperature: Hotter weather uses more energy.

  • Relative humidity: More humidity means you need more cooling.

  • Water availability: If water is low, air cooled chillers are better.

Smart technology, like IoT monitoring, helps you watch water, temperature, and energy use. This makes it easier to change your system for the best results.


Budget

You need to think about your money and your cooling needs. The cost to buy, run, and fix your chiller all matter. Here is a quick look at new market numbers:

Aspect

2023 Value (USD)

Projected 2032 Value (USD)

CAGR / Notes

Total Chiller Control Panel Market

1.2 billion

Growing at 5% CAGR

Demand for energy-efficient HVAC

Standard Control Panels

966 million

1.5 billion

Affordable and functional

Medium Capacity Panels (50-300 tons)

684 million

Over 1 billion

Good for many facility sizes

Energy Savings from AI Systems

N/A

Up to 30% reduction

AI-powered controls cut energy use


Newer chillers with AI controls can use up to 30% less energy. Cloud monitoring helps you save money by making your chiller work better and break down less. If you do not have much money, an air cooled chiller costs less to buy and fix. If you want to save money in the long run, a water cooled screw chiller with smart controls can lower your bills over time.


Pick a water cooled screw chiller if your building is big and needs lots of cooling. Air cooled chillers are better for small places. Think about what your building needs and look at the features. Talk to an HVAC expert for help. This way, you can choose the best chiller for good, steady cooling.


FAQ

What is the main difference between water cooled and air cooled chillers?

Water cooled chillers use water and a cooling tower to remove heat. Air cooled chillers use fans and outside air to cool your building.

How often should you maintain your chiller?

You should check your chiller every month. Clean coils, check water quality, and inspect moving parts to keep your system running well.

Can you use an air cooled chiller for a large building?

  • You can use an air cooled chiller for a large building, but it may not cool as efficiently as a water cooled system.

  • Water cooled chillers work better for high-demand spaces.

From Packaging to Production How Can Coil-Grooved and Valve-Grooved Packaging Equipment Help You Reduce Costs and Increase Efficiency?

2025-08-08

Across the entire industrial packaging supply chain, choosing the right packaging format is fundamental, while effectively leveraging intelligent equipment is key to boosting competitiveness. Whether it's flexible and economical coil-grooved bags or efficient and airtight valve-grooved bags, pairing them with professional intelligent bag-making equipment truly achieves a closed loop of "cost reduction, quality improvement, and efficiency enhancement." Today, we'll take you through two industry-leading bag-making machines—the Gachn Group AI Vision Inspection Valve-Grooved Bag Making Machine and the Gachn Group GM051 High-Speed Bagging and Coil-Grooved Machine—and see how they provide optimal solutions for diverse packaging needs!

 

Ⅰ.Valve Bag Production Upgrade: The Gachn Group AI Vision Inspection Bag Making Machine 3.0 delivers both efficiency and precision.

valve bag making machine

(Gachn group valve bag making machine working process diagram)

Valve bags, due to their strong sealing properties and high adaptability to automation, have become the preferred choice for industries such as cement, chemicals, and mineral powders. However, traditional production processes continue to plague businesses with low manual bag picking efficiency, high scrap rates, and difficult cost controls. Gachn Group's AI-powered visual inspection valve bag making machine 3.0 addresses these pain points with technological innovation.

 

Core technological highlights redefine valve bag production standards.

 

1. AI visual inspection replaces manual inspection.

The standard raw material visual inspection system uses high-precision cameras and AI algorithms to automatically identify defects such as holes, splices, and warp and weft deviations in the base fabric, as well as skewed corners, offset bottom stickers, and poor overlaps in finished bags, with a rejection rate as low as 0.05%. This eliminates one or two bag-picking workers per production line, completely resolving the industry challenges of "difficulty recruiting and inconsistent quality inspection."

2. Fully servo-controlled, delivering both speed and flexibility.

The machine boasts a stable operating speed of 120-130 bags per minute, far exceeding traditional equipment. It supports "one-click size change," easily switching between various sizes, including 380-910mm (woven bag width) and 80-200mm (valve port length), eliminating complex debugging and increasing flexibility in batch production. Visible cost reduction and efficiency gains.

Using technologies such as single-sided lamination and reduced overlap width, customers can save hundreds of thousands of yuan in material costs annually. A scrap rate as low as 0.1% minimizes raw material loss.

3. Worry-free after-sales service and continuous empowerment.

We provide on-site installation and commissioning, professional operator training, and free electronic control system upgrades within three years to ensure the equipment maintains industry-leading performance.

 

Applicable Applications: Sealing is essential in sectors ranging from building materials to chemicals.

Cutting&inserting&sewing&top hemming machine

(Gachn groupCutting&inserting&sewing&top hemming machine workflow diagram)

Preventing dust leakage in dusty building materials such as cement, gypsum powder, and putty powder.

Protecting against moisture and contamination in products requiring high sealing properties, such as fine chemical powders and pigments.

Suitable for automated filling lines for bulk powders such as mineral powder and coal powder.

 

Ⅱ.Speeding up loop bag production: The Gachn Group GM051 high-speed bagging and looping machine combines flexibility and efficiency.

Loop bags are known for their ease of operation and cost-effectiveness, making them widely used in grain, feed, and food industries. However, traditional production processes are plagued by fragmented processes, slow speeds, and frequent manual intervention, hindering large-scale production. Gachn Group's GM051 high-speed bagging and looping machine uses a fully automated process to efficiently transition from fabric roll to finished bag.

 

Core technology highlights make loop bag production more intelligent.

Fully automated processes reduce manual intervention. From outer bag unwinding, inner film wrapping, and bag tail sewing to loop forming, ultrasonic lip welding, and automatic stacking, the entire process is controlled by PLC and servo drive, eliminating the need for manual operation. A 10-inch touchscreen provides graphical control, making parameter adjustment simple and intuitive.

 

1. Continuous conveying process, increasing speed by 30%.

The innovative "mechanism follows the bag" design reduces bag start-up and stop times, achieving a stable operating speed of 30 bags/minute. The outer bag and inner film are precisely aligned (length error ≤ ±5mm), ensuring reliable and uniform welding and more consistent finished product quality.

 

2. Compatible with multiple specifications to meet diverse needs.

Supporting outer bag lengths of 650-1100mm, widths of 500-650mm, and inner film thicknesses of 0.015-0.05mm, it easily meets the packaging needs of diverse materials such as rice, beans, and feed. Compatible with both M-bags and flat bags for flexible switching.

 

3. Detailed quality and maximum durability.

Utilizing high-quality components such as German-imported Schneider servo motors and German KTR couplings, the frame base utilizes square tubes with a wall thickness of ≥6mm, and the main wall panels are ≥15mm thick, ensuring long-term stable operation. Safety features such as wire break detection and emergency stop protection ensure greater peace of mind during production.

 

Applicable scenarios: Flexible packaging needs for food and agriculture.

For household and wholesale packaging of foods such as rice, grains, and beans, the ring design allows for easy access.

For agricultural granular materials such as feed and seeds, the film and welding process provides moisture and dust resistance.

For industrial raw materials such as plastic granules, efficient mass production reduces packaging costs.

 

How to choose? Check your needs for the right fit.

If you're producing valve bags and require high speed, low scrap, and reduced labor, choose the Gachn Group AI Vision Inspection Bag Making Machine 3.0. It's particularly well-suited for large-scale, high-standard building materials and chemical companies.

If you're focused on loop bags and require flexible adaptation to multiple specifications and full process automation, choose the Gachn Group GM051 Slitting and Looping Machine. It's ideal for industries like food and agriculture, where ease of use is paramount.

Whether it's the efficient sealing of valve bags or the flexibility and practicality of loop bags, Gachn Group, driven by its mission of "Unlocking Key Technologies and Creating Customer Value," provides full-lifecycle support from equipment to service. Contact us for a consultation to receive customized bag-making solutions, making packaging production smarter and more worry-free!

 

Gachn Group's new generation valve bag making machine Technological innovation leads a new era of efficient production.

2025-08-08

In the valve bag making machine sector, Gachn Group's new generation FK008-III valve bag making machine, with its numerous innovative technologies and superior performance, has become an industry leader. It not only breaks through traditional limitations in key processes such as bag making, transfer, bag opening, and conveying, but also demonstrates significant advantages in technical parameters and equipment configuration, providing businesses with an efficient, stable, and cost-effective production experience

  • PP plastic valve bag making machine
  • PP plastic valve bag making machine
  • PP plastic valve bag making machine

 

Core Innovative Technologies Break Through Traditional Production Bottlenecks

Gachn Group's valve bag making machines feature innovative designs in several key mechanisms, effectively resolving numerous issues with traditional equipment.

In the bag transfer process, the Gachn Group utilizes a proprietary vacuum suction bag steering mechanism, enabling high-speed, vertical bag transfer for rapid and stable operation. Unlike the "claw-type" bag steering mechanisms used by other manufacturers, Gachn Group possesses its own core technology and intellectual property, avoiding patents held by renowned international equipment manufacturers and eliminating the risk of intellectual property infringement lawsuits.

The triangular bag opening mechanism is a further highlight, lacking consumable suction cups, significantly reducing ongoing maintenance costs. This mechanism utilizes a combination of negative pressure and a conveyor system to efficiently open the bag bottom while reducing noise and ensuring efficient and stable operation. Similarly, this proprietary core technology avoids international patents, eliminating the risk of intellectual property infringement lawsuits and providing peace of mind for manufacturers.

In terms of suction roller transfer, the bottom tape belt conveyors used by other valve bag making machines on the market are prone to bending, resulting in scrap. Furthermore, the higher the production speed, the more severe the kinking problem becomes. The belts also wear easily, making replacement difficult. Gachn Group's innovative suction roller conveyor mechanism is less prone to corner bending, significantly improving bag yields, enhancing equipment stability, and reducing production costs. This feature is unique to Gachn Group and is patented.

In addition, Gachn Group utilizes a professionally designed heat-sealing welding mechanism and unique technology, equipped with three hot air mechanisms, to ensure uniform air blowing and consistent dimensions. Servo-controlled switching of the air blow reversing axis allows for precise control of the welding on/off timing. Compared to other manufacturers' pneumatic cylinder control mechanisms, this system offers higher welding quality, precise adjustment of the air blow angle, and flexible adjustment of the heat seal width without requiring downtime, significantly enhancing production flexibility and efficiency.

 

Excellent Technical Parameters, Meeting Diverse Production Needs

The Gachn Group FK008-III valve bag making machine excels in bag making specifications and equipment parameters, adapting to diverse production needs.

It offers a wide range of bag specifications, with bag center length (L) ranging from 330-730 mm, bag width (W) from 300-620 mm, and bottom width (W1) from 80-120 mm, respectively. The valve opening length ranges from 80-200 mm.

The machine's specifications are equally impressive, with the main unit measuring 12.0 m (L) x 7.5 m (W) x 2.5 m (H), featuring a height adjustment mechanism at the bottom. The machine weighs approximately 17,000 kg. It utilizes a 3-phase, 380 Vac ±5%, 50 Hz, three-phase, five-wire system (CE standard), with an installed capacity of approximately 150 kW. The bag-making speed reaches a stable 130 bags/minute, with a maximum operating speed of 140 bags/minute.

Gachn Group's new-generation FK008-III valve bag bag-making machine integrates a visual inspection and waste removal system with core bag-making technology, creating a truly fully automated AI-powered closed-loop production system. Equipped with a 4K line-array infrared high-speed industrial camera and a black-and-white high-speed industrial camera, the visual inspection system accurately detects cosmetic defects in bags at a speed of 120 bags/minute. With a waste rejection rate of ≥96.5% and a false rejection rate of <0.15%, it enables real-time monitoring and intelligent screening of bag quality. Its detection logic is efficiently integrated with the core bag-making technology. When the visual system identifies a defective bag, a signal is instantly fed back to the bag-making unit's servo control system, triggering a cutting mechanism to precisely separate the defective bag. Simultaneously, the bag transfer unit's vacuum suction and dual servo drive systems immediately adjust the conveying rhythm to ensure that subsequent qualified bags are not affected.

 

Superior Equipment Configuration Ensures Stable and Efficient Operation.

PP plastic valve bag making machine

The Gachn Group FK008-III valve bag making machine is comprised of numerous high-quality components, all working together to ensure stable and efficient operation.

The machine features a comprehensive range of components, including 16 main components: a bag unwinder, micro-perforating device, unwinding traction device, bag-making device, and bag transfer device. The bag unwinder utilizes a passive unwinding mechanism, with the material unwinding driven by a traction motor. It is equipped with a magnetic powder brake, an air shaft, a swing arm for lifting the material, an end-of-roll alarm, and a floating tension bar, ensuring stable and reliable material unwinding and easy operation.

The micro-perforating device:utilizes a modular assembly system for micro-perforating needle rollers. Damage to any part requires only the corresponding module to be replaced, making it economical and cost-effective. The micro-perforation size adjustment mechanism utilizes a screw and handwheel design for easy adjustment. The unwinding traction device is independently controlled by a servo motor, and the clamp rollers are opened and closed by a manual valve-controlled cylinder, simplifying material threading.

The bag-making unit:includes mechanisms for pulling material, color mark alignment, and rear-end cutting. The color mark position is adjustable, and bag-making can be performed in two modes: color mark alignment and fixed-length. It also features a bag-ready detection function and manual bag-making functions. The bag-transferring unit utilizes a vacuum negative pressure system and dual servo segmented control to ensure stable, timely, and reliable bag movement. A photoelectric detection system generates an alarm and stops the bag-making section if transfer fails.

The bag-opening unit:includes an opening unit and a mouth-opening unit. The opening unit utilizes a separate servo conveyor combined with negative pressure blower control, while the mouth-opening unit is also controlled by a separate servo, ensuring stable and widest opening. The forming unit consists of a triangular forming unit and a belt conveyor. The triangular forming unit is efficient, stable, and has an adjustable width, while the belt conveyor prevents the opening from rebounding.

The welding unit:utilizes an ultra-high-temperature heating gun with adjustable temperature, equipped with thermocouple temperature detection and a power-off protection device. A servo-controlled steering axis controls the airflow direction, and the nozzle width is adjustable. The folding unit uses multiple folding plates to create a fixed folding path, and the folding width is adjustable via a lead screw. The conveyor system for valve and bottom stickers incorporates multiple mechanisms, ensuring simple and reliable unwinding. It is equipped with a web-correcting device, and the cutter roller and material transfer mechanisms are independently controlled by servo motors, ensuring accurate cutting length and welding position. The finished product stacking conveyor features counting and stacking functions, with adjustable parameters. Protective devices comply with relevant regulations to ensure production safety. The visual inspection and waste removal system, electrical system, and pneumatic system are also well-equipped, providing strong support for equipment operation.

In addition, the equipment's electrical configuration and mechanical components are imported, high-quality international brands, such as Schneider and Weidmüller for low-voltage power distribution, German Schneider for PLC, servo, and touch screen, Panasonic for sensors, and Taiwan's Xinbao for servo planetary reducers, ensuring stable performance. All machined parts are surface-treated, exposed parts are made of high-quality materials, and transmission components are made of special steel that has undergone quenching and tempering treatment, ensuring equipment durability.

 

Comprehensive service and support ensure worry-free production.

Professional on-site technical training provides hands-on instruction on equipment installation and commissioning. After the equipment is installed and commissioned, we will dispatch experienced technicians to the customer's factory to provide face-to-face technical guidance. The training covers key points such as equipment operation procedures, parameter adjustment techniques, common fault diagnosis and repair methods. During the training, the customer is required to arrange for one to two technicians to participate to ensure that relevant personnel master all equipment operation and maintenance skills, laying a solid foundation for stable equipment operation.

Efficient remote team support for rapid response to needs. In addition to on-site services, Gachn group has also established a professional technical team to provide comprehensive remote after-sales service. Whether customers have questions about equipment operating parameter settings, troubleshoot unexpected minor problems, or require technical consultation during production, they can contact our remote service team by phone, video, or other means. Leveraging their in-depth knowledge of the equipment, the team will provide timely solutions and remotely assist in troubleshooting and resolving issues, minimizing production downtime caused by equipment issues and ensuring continuous production.

Gachn Group's new generation FK008-III valve bag making machine, with its innovative technology, superior performance, sophisticated configuration, and comprehensive service, provides valve bag manufacturers with an efficient, stable, and cost-effective solution, leading the industry to new heights of production. Choosing Gachn Group guarantees efficient production.

Comprehensive Guide to CNC Press Brake From Principles to Usage Steps

2025-08-08

In the sheet metal processing industry, the "CNC Press Brake (Computer Numerical Control Press Brake)" is becoming a core device for companies to improve production line efficiency and product precision. This article will provide a comprehensive introduction to the workings and practical applications of CNC press brake from four aspects: principle, structure, advantages, and usage steps.

 


 

1. What is a CNC Press Brake?

A CNC press brake is a device that precisely bends sheet metal by controlling the movement of the slide and backgauge. It uses a CNC system to control the movement of each axis, combined with hydraulic drive, die pressure, and angle detection, to achieve precise, stable, and efficient sheet metal bending.

Depending on the drive method, common types include:

 

✅ Electro-hydraulic synchronous bending machine (servo-hydraulic control, mainstream configuration)

 

DE68T electro-hydraulic CNC bending machine

 

✅ Torsional axis synchronous bending machine (simple structure, suitable for general needs)

 

Copper plate pure electric press brake

 

✅ Pure Electric servo bending machine (high-end energy-saving model, suitable for small precision workpieces)

 

torsion shaft bending machines

 

 


 

2. The main components of CNC bending machine

Module Name

Function Description

CNC System

Controls slide travel, backgauge position, angle compensation, and program calls.

Upper and lower molds

Key tools for forming bend angles and shapes.

Slider device

Drives the upper die up and down, applying pressure to form the shape.

Hydraulic System

Provides pressure to control the synchronized and stable operation of the slides.

Backgauge

Positions sheet length and controls bend dimensions.

Compensation System

Automatically adjusts for angular errors caused by machine tool deformation (e.g., mechanical/hydraulic compensation).

Safety protection devices

such as light curtains, emergency stop buttons, and access control interlocks, enhance operational safety.

 


 

3. The main advantages of CNC bending machines

1. High Precision and Excellent Repeatability

The CNC system achieves positioning accuracy of ±0.01mm, ensuring high bending angle consistency.

 

2.Fast mold changeover and simple operation

Using program calls and graphical guidance, mold and process switching can be completed in minutes, making it suitable for high-variety orders.

 

3.Adaptable to Flexible Manufacturing

Supports complex bending paths and multi-stage bending programs, making it suitable for customized, low-volume, and high-volume production.

 

4.Ample room for intelligent upgrades

Automated loading and unloading, robotic collaboration, and angle detection systems can be expanded to enable automated production line deployment.

 


 

4. Correct use steps of CNC bending machine

1. Power-On Inspection:

Check the hydraulic oil level;

Confirm that the power supply, voltage, and air pressure are safe;

Check that the mold is securely installed and that the safety devices are intact.

 

2. Programming:

Enter the bending angle, length, sequence, and backgauge position;

Import machining drawings via the graphical interface or USB;

Set compensation parameters and limit switches.

 

3. Plate Positioning and Operation:

Place the plate on the workbench, close to the back gauge.

A foot pedal controls the movement of the slide to perform the bending.

The system automatically controls the angle and stroke to avoid over- or under-pressure.

 

4. After bending is completed:

Check the workpiece dimensions and angles;

Turn off the power and clean the equipment;

Keep daily maintenance records.

 


 

5. Applicable industries and typical applications

CNC bending machines are widely used in:

 

Sheet metal fabrication: Chassis, cabinets, brackets

Automotive parts: Body frames, support beams

Home appliance manufacturing: Refrigerator doors, air conditioner casings

Power distribution industry: Control cabinets, switch cabinet door panels

Stainless steel products industry: Cabinets, stair railings, door and window components

 


 

6. Summary

With the continuous advancement of industrial automation and intelligent manufacturing, CNC press brakes are gradually replacing traditional manual bending and becoming the "intelligent backbone" of sheet metal production lines. For companies considering equipment upgrades or improving processing precision, choosing a CNC press brake with stable performance, high intelligence, and easy operation is undoubtedly a key step in achieving both efficiency and quality improvements.

 

If you have further questions about equipment selection, operator training, or export configuration, please feel free to contact the ZYCO technical team. We will provide you with professional and efficient one-stop solutions.

Bedknife Sharpening Of Reel Mower

2025-08-07

If replacing the bedknife it is important to use the following procedure:

 

1. Remove the bedbar from cutting unit.

 

2. Remove the screws from the bedbar using a socket wrench and a bedknife screw tool. Discard the screws.

 

3. Use a scraper to remove all rust, scale and corrosion from bedbar surface.

 

4. Lightly oil the bedbar surface before installing the bedknife.

 

5. Make sure that screw threads in the bedbar are clean.

 

IMPORTANT: Do not use an impact wrench to tighten the screws into the bedbar.

 

6. Use new screws to secure bedknife to bedbar. Apply antiseize lubricant to the threads of new screws. Do not apply antiseize lubricant to the taper of the screwheads.

 

7. Install all screws but do not tighten.

 

8. Using a torque wrench and bedknife screw tool, tighten the 2 outer screws to 10 in- lb (1 N-m).

 

9. Working fromthe center of the bedknife toward each end, tighten screws from 200 to 250 in- lb (23 to 28 N- m).

 

10. Grind the bedknife after installing it to the bedbar.

 

Since there can be variations in the mounting surface of the bedbar, it is necessary to grind the bedknife after installing it to the bedbar.

 

When grinding the bedknife, remove only enough material to make sure the top surface of the bedknife is true. Be careful not to overheat the bedknife. Remove small amounts of material with each pass of the grinder. Also, clean and dress grinding stone often during the grinding process.

 

Because the top grind angle on bedknives is critical for edge retention, and therefore after- cut appear ance,Using special service tools for accurately measuring the top grind angle on all bedknives.

 

IMPORTANT: Do Not grind the bedknife below it’s service limit. Operating the cutting unit with the bedknife below the service limit may result in poor after- cut appearance and reduce the structural integrity of the bedknife for impacts.

 

A lead-in chamfer provides a softened entry for the leading side of the reel blade helix as it approaches the bedknife. This helps eliminate rifling caused by heavy contact and vibration. A lead- in chamfer is ground into all new Reelmaster bedknives. The original chamfer should last for the first 40%of the bedknife service life. Check and re-grind the lead- in chamfer as necessary.

 

The idea is to get a grind in place without spending a lot of time making sure it is exact. Using a file to make the lead-in is a perfectly acceptable method. It is important not to make the lead-in too long or you will notice that there is a streak left behind at the edge of the cutting unit as the reel will not cut well in the area

of the grind or may adversely affect the overlap area.

 

The Edge Max bedknife includes a leading edge of harder steel.

 

The Edge Max bedknife Holds an edge twice as long as a standard bedknife, and reduces the need for adjustments, backlapping and grinding.

 

Set the bedknife to reel adjustment on an Edge Max bedknife as usual. Light contact while running on the ground.

 

There are no other special requirements.

 

A dull knife must be sharpened.

 

If backlapping is part of your maintenance practice, be prepared to backlap for two to three times the amount of time as compared to a standard bedknife. Front face grinding is acceptable in moderation.

 

Any facing or grinding must be done with exacting tolerances. Do not use a hand held grinder

 

Using a diamond grinding wheel is recommended to prevent overheating or damaging the bedknife edge while grinding.

 

Dress the stone more frequently. Before starting, and at least once during grinding. One pass to dress. Multiple passes will cause the stone to load up.

 

When grinding, remove smaller amounts of material

(a shallower cut).

 

Expect a different spark pattern.

 

Bedknife design must allow for maximum material to dissipate heat and yet allow the remaining uncut grass under the bedknife.

 

Unfortunately, there is no set rule for space left under the knife, nor can there be. This is due primarily to surface density and turf conditions. There is no measurable plane that works, other than, your mower, in your turf.

 

The only thing that is absolute is that while on the bench, the bedknife can not touch the height of cut adjusting tool. There must be a reasonable space between the bedknife and height of cut adjusting tool.

 

To look at that in a different manner, place the cutting unit on a table resting on the rollers so as you can look at the end of the cutting unit. The bedknife can not touch the table top. This is the absolute! Everything else depends on the agronomic conditions of the turf.

 

Listed here are popular Greens mower bedknives and their recommended operating range.

 

Due to the height of cut variations on a fairway and the requirements of cutting conditions there is another line of bedknives for the fairway or higher height of cut ranges.

 


 

Effective Strategies to Quickly Increase Green Speed

2025-08-07

Green speed is an important indicator of green quality, and many golf courses face the challenge of not meeting the required speeds for different tournaments. Here are some short-term effective methods to enhance green speed:

Adjust Mower Bed Knife Angle: Increasing the front angle of the bed knife can improve post-mowing green speed and enhance the smoothness of the cut. A high-quality bed knife for mowers can make a significant difference in achieving better cutting results.

Temporary Cleansing: By raising the height of the grooming brush, you can avoid disturbing the soil while also increasing the gap between the reel and the bed knife to reduce equipment load and improve cut uniformity.

Change Cutting Direction: Utilizing a cross-cutting pattern and reverse mowing can enhance upright grass growth and ensure a level hitting surface, thus increasing speed.

Moisture Control: Reduce automatic irrigation and opt for manual watering to prevent localized wetness, helping to keep the greens dry and speedier.

Adjust Mowing Height: Properly lowering the mowing height according to the 1/3 cutting rule can avoid damaging the turf while enhancing speed.

Adjust Mowing Frequency: Increasing the frequency of mowing, especially by mowing twice a day during high-speed demands, improves grass density and smoothness.

Optimize Mowing Speed: Choosing the right mower and blade type, and ensuring the mowing speed matches the grass height, can enhance cutting quality. A precision bed knife for golf course greens is crucial in ensuring a clean and even cut for better results.

Maintain Sharp Blades: Keeping the bed knife and reel sharp, along with proper blade spacing, ensures a clean cut and improves green speed. Regular sharpening is essential for maintaining the effectiveness of a durable bed knife for golf course mowers.

Rolling: Rolling the greens is an effective and safe method for quickly improving speed; studies show significant differences in speed before and after rolling.

Implementing these strategies can effectively increase green speed to meet tournament requirements.

Contact Us

Whether you are a gardener, landscape designer, or lawn maintenance company, our aeration blades are your ideal choice. If you are interested in our products or have any questions, please feel free to reach out to us through the following:

· Website: https://www.dxlfgolf.com/

· Mobile: +86 13981920100

· Email: 2556034587@qq.com / lfgolf888@gmail.com

· Address: Bowang Town, Bowang District, Ma'anshan City, Anhui Province, China

Elevate Your Golf Experience with EZGO Golf Carts!

2025-08-07

There's nothing quite like a perfect day on the golf course, and having a high-quality golf cart can significantly enhance your overall experience. That’s where EZGO Golf Carts come in! Established in 1954, EZGO has built a trusted reputation for delivering top-notch quality and innovative designs that cater to golfers' needs around the globe.

Why Choose EZGO Golf Carts?

  1. Exceptional Performance: With options for both electric and gas-powered models, EZGO carts are engineered for optimal performance. Experience smooth navigation on the varied terrain of any golf course, allowing you to focus on your game rather than your ride.

  2. Unmatched Comfort: Comfort is key when you're spending hours on the course. EZGO carts feature spacious seating with cushioned support, ensuring you can relax between holes and enjoy the journey as much as the game.

  3. Durability That Lasts: Constructed from high-quality materials, EZGO golf carts are built to withstand the rigors of outdoor use. Rain or shine, these carts maintain their performance and aesthetic appeal, promising years of reliable service.

  4. Eco-Friendly Options: With growing concern for our planet, EZGO’s electric models stand out. They operate quietly, produce zero emissions, and minimize their ecological footprint, allowing you to enjoy golf while caring for the environment.

  5. Customizable Features: EZGO carts are versatile and can be customized to fit your style and preferences. From different seating options to storage upgrades, you can tailor your cart to enhance your golfing experience further.

Your One-Stop Shop for EZGO Accessories

To complement your EZGO golf cart, we proudly offer a comprehensive selection of genuine EZGO parts and accessories. From routine maintenance items to performance upgrades, our inventory ensures your cart remains in peak condition. Our dedicated team is here to help you find exactly what you need, ensuring your time on the course is hassle-free.

Get in Touch with Us!

We invite you to explore the world of EZGO Golf Carts and the array of accessories we offer. Whether you're looking to purchase a new golf cart or need parts for your existing model, our knowledgeable team is ready to assist you.

We look forward to providing you with the finest golfing experience. Let’s make your next round of golf more enjoyable with EZGO!

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