Penguin Chillers 1 1⁄3 HP XL Glycol Chiller Product Specifications

Chiller Comparison Chart – XL Glycol Chiller line

Sizing a Glycol Chiller for Brewing

To size a chiller you need to determine what’s the worst case scenario when it comes to how much cooling you’ll need. While you could size a chiller to be able to cold crash all of your tanks at the same time, that’s not how a typical brewery operates. 95%+ of our customers would be covered using our general rule of thumb for sizing (below the chart).  The suggestions in the chart assume the fermenter is insulated with a neoprene jacket or better and ambient conditions are roughly 80F. If you will be operating in hotter or conditions or without an insulated tank use the suggestion from the next sized up tank

Note: For the purposes of the chart “cold crashing” is only referring to the +/- 18hr period of active temperature drop. Once at a cold temperature use the “maintain cold” column for holding at cold temps to carbonate/clarify/etc. It’s common for the industry to refer to any part of the cold process as the cold crash, but for chiller sizing there is a significant difference between dropping the temperature and holding cold temperatures.

We typically break down a setup into a block of 4 tanks. Tank #1 is cold crashing, Tank #2 is maintaining cold, Tanks #3&#4 are fermenting. If there are a mix of tank sizes, the biggest is the tank is the one cold crashing, and the next biggest is the one maintaining cold.

If you have more than 4 tanks, the cycle repeats. Tank #5 is cold crashing, Tank #6 is maintaining cold, tanks #7&#8 are fermenting. If there are a mix of tank sizes you first fill “cold crashing” spots from both blocks with the biggest and 2^nd biggest tanks, then fill the “maintaining cold” spots with the next biggest tanks.

Tank#1 – Cold crash

Tank#2 – Maintaining Cold

Tank#3 – Fermenting

Tank#4 – Fermenting

Tank#5 – Cold Crash

Tank#6 – Maintaining Cold

Tank#7 – Fermenting

Tank#8 – Fermenting

Example: 1x 7BBL, 2x 5BBL, 1x 3BBL an 3x 2BBL tanks:

Tank#1 – 7BBL Cold crash = 6,000 BTU/hr

Tank#2 – 5BBL Maintaining Cold = 1,500 BTU/hr

Tank#3 – 2BBL Fermenting = 325 BTU/hr

Tank#4 – 2BBL Fermenting = 325 BTU/hr

Tank#5 – 5BBL Cold Crash = 4,300 BTU/hr

Tank#6 – 3.5BBL Maintaining Cold = 1200 BTU/hr

Tank#7 – 2BBL Fermenting = 325 BTU/hr

In this scenario the BTU/hr adds up to 13,975 BTU/hr, you can then use this number to select an appropriately sized chiller that provides at least this many BTU/hr.

Recommended Glycol Mix

We recommend using a 35-40% glycol to 60-65% water mix for our brewing customers operating at approximately 28F. Other application may require a different mix depending on desired operating temperature.

Easy mix suggestions

1 Gallon of Glycol + 1.5 Gallon of Water = 40% Glycol Mix

1 Gallon of Glycol + 1.75 Gallon of Water = 36.3% Glycol Mix

Setup for Brewing Applications

With the controller on the the chiller set to 28F, you need a way to regulate the flow of cold glycol out of the chiller to each fermenter so that a variety of temperatures can be maintained across multiple fermenters. There are 2 main ways to accomplish this, our chillers can be used with either method.

• One pump per fermenter: A submersible glycol pump is put into the reservoir, tubing is run out to a single fermenter and back to the chiller. The pump is plugged into a controller that monitors fermenter temperature. The flow of cold glycol is regulated via the pump turning on/off as needed for that fermenter. We sell this style of pump/tubing/controller – see our glycol chiller accessory package.
• Glycol Loop: A single external continuous duty pump runs 24/7 to provide flow through a network of pipe in the brewery. There are solenoid valves on the supply line that are wired into a centralized control panel for the entire operation. The flow of glycol is regulated via opening/closing of the solenoids to provide glycol to a particular fermenter as needed. While our chiller will work for this type of install, we do not carry any of the products needed to setup a glycol loop.

Penguin Chiller Glycol Chiller Owner Manual

Penguin Chiller Product Warranty

Penguin Chillers Product FAQs

1) Can my chiller be installed and used outside?

• Cold Therapy Chillers: These can be used indoors and outdoors, except in freezing conditions.
• Standard Water Chillers: Not intended for outdoor use at all.
• Commercial Chillers: Excluding the all-in-one Commercial Water Chiller, these are ready for outdoor use, regardless of the elements.

2) Can I use a Standard Water Chiller for cold therapy?

While the temperature range of our standard water chillers might be suitable for some cold therapy applications, we generally advise against it for a few reasons:

• Durability Concerns: Standard water chillers are not specifically designed for the use in outdoor environments and so the rigors of cold therapy applications could lead to damage on internal components.
• Missing Pump: Additionally, unlike our Cold Therapy Chiller, standard water chillers don’t have built-in pumps.

Safer and More Effective Cold Therapy Solution:

We recommend considering our dedicated Cold Therapy Chiller for several reasons:

• Built for Cold Therapy: It’s specifically designed to survive outdoors except in freezing conditions.
• Integrated Pump: The built-in pump ensures proper water circulation for optimal cold therapy effectiveness.

3) How do I prevent damage to my chiller?

• Regular Filter Cleaning: Cleaning the filter weekly helps maintain proper water flow and prevents ice buildup.
• Maintain Proper Water Levels: Ensure your chiller has the recommended water level so that it maintains optimal performance.
• Avoid Running the Chiller Dry: Never run your chiller without sufficient water flow. If the water level is low, it can lead to internal damage to the heat exchanger.

4) How often should I clean my Penguin Chiller filter?

We recommend checking and cleaning your Penguin Chiller filters about once a week. Even if the filters appear clean, built-up debris can restrict water flow to the heat exchanger.

Why is cleaning the filter important?

Restricted water flow can cause the water in the heat exchanger to freeze. The expanding ice can crack the heat exchanger, leading to damage from lack of upkeep, which is not covered by warranty. Regular cleaning helps prevent this issue, so your chiller will operate efficiently for years to come.

5) Do Penguin Chillers have built-in pumps?

With the exception of the Cold Therapy Chiller, none of Penguin Chillers’ chillers have built-in pumps. Chillers are used in various setups, so customers should choose the pumps needed for their specific project.

6) What size or type of pump should I use?

• Water chillers: We recommend pumps between 500 gph and 1,800 gph to achieve a minimum flow rate of 250 gph.  Submersible pumps are commonly used for their simplicity. Pump size should compensate for factors like pipe length, fittings, and head height, so Penguin Chillers offers Danner water pumps ranging from 500 gph to 3600 gph.
• Glycol chillers: Space limitations might restrict pump options, so Penguin Chillers recommends specific glycol pump lines that work well with their units.
• Commercial water chillers: A measurable flow rate of 1,200 gph to 2,500 gph is recommended, but the pump size can vary depending on the application.

7) What's the lowest temperature my chiller can reach?

This is a common question, but there’s no one-size-fits-all answer. It depends on several factors:

• Water Chillers: We recommend not running them continuously below 37°F. During testing, we reached 36°F with 5 gallons of water. Factors like your target temperature, liquid amount, and ambient conditions all affect how low your chiller can achieve.
• Glycol Chillers: Similar to water chillers, the lowest temperature depends on various factors. We recommend not running them continuously below 5°F, However in testing (with no heat load), we reached -15°F.

8)  Do Penguin Chillers have built-in tanks?

• Water Chillers: No, they don’t. Their internal piping holds less than half a gallon of water.
• Glycol Chillers: Standard models have reservoirs ranging from 1.25 to 3 gallons. Stainless Steel XL models have 8-30 gallon reservoirs, and commercial units have a 30-gallon reservoir. Check individual product details for specifics

9) How loud are Penguin Chillers?

Our chillers operate at a relatively quiet level. Most customers find them quieter than expected, but specific sound ratings (DBA) are available on each product page.

10) How much heat does a chiller put out?

Chillers remove heat from one area (liquid) and then release it into the surrounding air. So, the amount of heat released depends on how much heat needs to be removed from the liquid. It’s difficult to give a direct answer, but proper ventilation is crucial for efficient chiller operation

11) Does my chiller need ventilation?

Yes! Chillers need ventilation for proper heat transfer. If they’re in a confined space, such as a cabinet, then they won’t function correctly. Ventilation allows excess heat to dissipate so your chiller will continue running efficiently.

12) Why did my fermenter's cold crash stall at 40-50F?

Several reasons could explain this:

• Chiller malfunction: If your chiller maintains its set point and cycles normally, then it’s likely not the culprit. However, if it runs constantly and can’t reach the desired temperature, contact Penguin Chillers technical support for assistance.
• Heat transfer issue: If heat isn’t being pulled away from your product (e.g., beer) fast enough and transferred to the glycol, this could be the issue.
• Frozen glycol: A stall during cold crashing is actually often caused
  by the glycol mixture being too cold. If your glycol is too cold, it can freeze your product, creating an insulating layer that prevents proper heat transfer. To solve this, raise the glycol temperature for a few hours so it can melt any ice buildup.

Common operating temperatures:

• Glycol chiller: 28°F. Colder temperatures might freeze your product. If 28°F is still too cold, raise the glycol temperature to 30°F-32°F. Alcohol content in your product might also require a slightly higher setting. Avoid testing with water only.
• Other factors: Glycol level, flow rate, or incorrect temperature reading could also be issues. Contact Penguin Chillers technical support for troubleshooting help