What to Review Before Your Cooling System Is Pushed to the Limit

By John McCoy, Technical Support Manager | G&D Chillers

As summer approaches and production ramps up, cooling systems are often pushed harder than at any other time of year. Longer run times, higher ambient temperatures, and increased thermal loads can expose problems that aren’t visible the rest of the year.

We spoke with John McCoy of G&D Chillers’ Technical Support team about what he sees most often during peak season — and what customers can do now to avoid issues when systems are under sustained demand.

How Peak Season Impacts Process Cooling Systems

Q: From a tech support perspective, what changes when peak season hits?

John:  The biggest change is duration. Systems aren’t just working harder — they’re working longer.

By late spring and early summer, we see extended run times with fewer breaks, combined with higher ambient temperatures. That puts pressure on heat rejection, compressors, and fluid systems all at once.

Another factor people sometimes overlook is added load. If a facility has expanded since last summer — added tanks, processes, or equipment — that additional load may not have caused issues during cooler months. But once summer temperatures hit, reduced system capacity plus added load can make it difficult to maintain temperature.

Most peak‑season problems don’t start in summer. Peak load is usually what exposes them.

What to Review Before Summer Production Ramps Up

Q: What are the first things you recommend customers evaluate before peak demand?

John: I focus on how the system behaves over time, not just how it performs at one moment.

Some key things to review:

• Can the system hold temperature during long, continuous runs?
• Do pressures climb as ambient temperatures increase?
• Does recovery take longer after high‑load periods?
• Have any loads been added since last summer that the system now has to support?

This is also when preventative maintenance really matters. A scheduled maintenance check before peak season can prevent a lot of problems later. Small checks — filters, fluid condition, connections, airflow — can keep small issues from turning into big wrecks when the system is running full out.

If something looks different than last year, it’s usually worth digging into. Those trends don’t correct themselves.

Common Cooling System Failure Points Under Sustained Load

Q: What issues show up most often once systems are under continuous demand?

John: Heat rejection is a big one, especially during high ambient conditions.

We also see fluid management issues — flow restrictions, fouled heat exchangers, filtration problems — things that reduce efficiency and temperature stability over time.

Another common sign is systems running too close to their limits. Higher pressures, more frequent alarms, less margin. That’s usually where small issues start turning into bigger ones.

Why Service Accessibility Matters During Peak Season

Q: Why does serviceability become more critical in summer months?

John: Because when a system is running nonstop, downtime gets expensive fast.

If components are hard to access, even minor issues take longer to resolve. During peak season, that lost time adds up quickly.

Systems designed with service in mind are simply easier to support when demand is high and schedules are tight. You notice that difference right away when something needs attention in July.

The Role of Technical Support in System Performance

Q: How does G&D Chillers’ support approach help during peak demand?

John: Support is part of system performance. Always has been.

At G&D, we stay involved long after startup. When customers call our 24/7 technical support, they’re talking with people who understand the equipment and the application.

That familiarity cuts down on guesswork, speeds up troubleshooting, and helps prevent small issues from becoming outages.

Practical Advice Before Peak Cooling Demand Hits

Q: What’s your biggest recommendation heading into peak season?

John: Don’t wait for a failure to confirm there’s a problem.

If temperatures take longer to pull down, pressures trend higher than usual, or the system just feels different, it’s worth looking into early. In most cases, issues are manageable if they’re caught early.

Emergency calls are harder on everyone. Planning ahead usually isn’t.

When to Reach Out for Support

If you’re preparing for higher production loads, reviewing added equipment, or want to verify how your cooling system is performing under sustained demand, G&D’s engineering and technical support teams are available.

Contact us

Committed to Cold

More than equipment — long‑term cooling partnerships with 24/7 technical support

gdchillers.com | 800.555.0973

Start with Age — But Don’t Stop There

For most wineries, the chiller is one of the hardest-working pieces of equipment on site. It protects fermentation, stabilizes storage, and safeguards product quality year-round.

But every winery eventually faces the same question:

Do we keep maintaining and repairing this system — or is it time to replace it?

The answer isn’t always obvious. Here’s how to evaluate the decision strategically.

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Evaluate Age — But Look Deeper

Chillers typically have a service life of 10–15 years, depending on usage, environment, and maintenance history.

• Under 8–10 years old: Preventative maintenance and minor repairs are usually the most cost-effective path.
• 10+ years old: It’s time to evaluate performance, efficiency, and risk exposure more closely.

Age alone doesn’t dictate replacement — but it should trigger a deeper assessment.

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When Maintenance and Repair Still Make Sense

Continuing to maintain and repair your existing system is usually the right choice when:

• Compressor runtime hours are within expected limits
• Repairs have been minor and infrequent
• Energy consumption is stable
• The system has adequate capacity during peak harvest
• Refrigerant and replacement parts are readily available

Preventative maintenance and timely repairs — including coil cleaning, refrigerant checks, electrical inspections, and control calibration — can significantly extend system life and preserve reliability.

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When Replacement Becomes the Smarter Decision

There are clear indicators that a chiller is approaching the end of its practical lifecycle.

1. You’re Operating at Maximum Capacity During Harvest

If your chiller runs continuously during peak fermentation with no margin, you’re operating without redundancy. That increases production risk.

2. Major Components Are Failing

Repeated compressor replacements, electrical failures, or refrigerant leaks over a short period often signal declining system integrity.

3. Energy Costs Are Climbing

Older equipment typically operates less efficiently. Modern systems can offer meaningful gains in energy performance and part-load efficiency.

4. Your Production Has Expanded

If tank volume or storage has increased but cooling capacity hasn’t, the system may simply be undersized for current operations.

5. Refrigerant Phase-Out Concerns

Legacy refrigerants can become expensive or difficult to source. At some point, maintaining compliance becomes less economical than upgrading.

“The biggest mistake we see wineries make is waiting for a failure to force the decision. By the time a chiller goes down in peak fermentation, you’re already in crisis mode. A planned upgrade protects both production quality and peace of mind.”
— Andy Backer, North American Sales, G&D Chillers

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The Real Question: What Is Downtime Worth?

The cost of a chiller failure during peak fermentation often exceeds the investment required for a planned replacement.

Waiting for failure shifts the timeline from controlled capital planning to emergency response — which typically costs more and introduces operational disruption.

Planned replacement allows for:

• Proper load calculations
• Right-sizing for current and future growth
• Improved energy efficiency
• Consideration of redundancy strategies

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A Practical Evaluation Strategy

Before making a decision, wineries should consider:

• A performance assessment before peak season
• A load analysis based on actual tank and facility volume
• An efficiency comparison between current and modern systems
• A review of maintenance and repair history

Sometimes the right answer is ongoing maintenance and repair.
Sometimes it’s strategic replacement.

The key is evaluating your system before it becomes a production liability.

Don’t wait for harvest to test your system.
Contact G&D Chillers for a pre-season cooling assessment and capacity review.

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By John McCoy, Technical Support Manager – G&D Chillers

As severe winter storms sweep across the country this week, we’re seeing conditions that pose a serious risk to glycol chillers, especially in areas experiencing heavy ice accumulation and unexpected power outages. While our November Winter Maintenance Tips guide covered seasonal prep, these storms introduce additional challenges that require immediate attention.

Below are the top urgent considerations to help prevent catastrophic chiller damage during the current cold snap.

1. Watch for Falling Ice Above Your Chiller

Ice and snow buildup on roofs, overhangs, and structures near your chiller can break loose without warning.
We’ve seen this scenario too many times:

A sheet of ice falls → crushes coils or fan assemblies → leads to total chiller failure.

Take these quick steps:
✔ Inspect roofs and overhangs for ice accumulation
✔ Safely clear icicles and snow over chiller placements
✔ Use caution—falling ice can be dangerous

Even a single ice drop can destroy a chiller. A few minutes of prevention can save days or weeks of downtime.

2. Keep Fluid Flowing — It's Your Best Freeze Protection

Fluid movement is the difference between a system that survives freezing temperatures and one that fails.

Just like rivers rarely freeze while lakes do, circulating glycol remains far more freeze‑resistant than stagnant fluid.

What to do:

✔ Keep power connected to your chiller during winter
✔ Confirm pumps are running in freezing conditions
✔ Monitor flow and pressure periodically during extreme cold

When storms cause unexpected power outages, the risk increases dramatically.

3. Power Outage? Act Fast. Here’s What Matters Most.

Short outages (1–2 hours) are typically fine.
But in extended outages with low ambient temps, your chiller becomes vulnerable to rapid freezing.

Your best protection options:

Best:
🔸 A generator—it doesn’t need to power the full chiller, just the pump to keep glycol circulating.

Minimum fallback:
🔸 A small space heater placed in front of the chiller, with tarps or covers to retain heat

Worst‑case scenario:
🔸 Drain the glycol reservoir and exposed plumbing
This prevents ice expansion from rupturing components—similar to a water-filled glass bottle in a freezer.

4. Maintain the Correct Glycol Concentration

Your glycol mixture is critical to protecting your chiller in extreme weather.

👉 Stay between 35–40% glycol to water. 
Below 35% = freeze risk
Above 40% = reduced efficiency & pump strain

If you haven’t tested your glycol recently, do it now—especially if the storm hits your region.

5. Need Help? Our Tech Support Team Is Standing By.

These storms are hitting rapidly in multiple regions, and our team is already helping customers respond to ice damage, freezing, and emergency prep.

If you need guidance on:
• Glycol concentration
• Power outage response
• Freeze protection
• Flow issues
• Ice accumulation hazards

👉 Contact G&D Tech Support: techsupport@gdchillers.com or give us a call 541.345.3903

We’re here to help keep your system safe through this extreme weather.

Stay Safe and Keep Your System Protected

Winter storms bring unpredictable conditions, but with quick action and the right steps, you can prevent the most common and costly types of chiller damage.

By John McCoy, Technical Support Manager

As temperatures drop, your cooling system still plays a vital role—especially for process applications that require consistent performance year-round. At G&D Chillers, we understand that winter can be tough on chillers if proper maintenance steps aren’t taken. Preventing freeze damage, corrosion, and inefficiency now can save costly repairs and downtime later.

Here are our top winter maintenance tips to keep your chiller running smoothly all season long.

1. Inspect and Protect Against Freezing

Even when ambient temperatures fall, residual water inside a chiller can freeze and expand, causing damage to pipes, evaporators, and heat exchangers.

Best Practices:

• Drain and flush unused chillers before extended shutdowns.
• Use a glycol-water mixture suited for your region’s lowest temperatures.
• Insulate exposed piping and components to minimize heat loss.

A simple inspection before the first freeze can prevent expensive mid-winter breakdowns.

2. Check Glycol Concentration and Quality

If your chiller operates during the winter, glycol concentration is crucial. Too much glycol can reduce efficiency, while too little can cause freezing.

Pro Tip: Test your glycol concentration and adjust it according to manufacturer guidelines—typically between 35–40%. Replace degraded glycol, as contamination can lead to corrosion or fouling within the cooling loop.

3. Maintain Proper Fluid Flow

Cold weather can change fluid viscosity, reducing flow and overall system performance.

Keep things moving by:

• Inspecting pumps, valves, and strainers for blockages or wear.
• Monitoring flow rates and pressure drops—sudden changes can indicate developing issues.
• Gradually warming up your chiller before resuming full operation after long idle periods.

4. Monitor Electrical Components

Cold weather can stress electrical systems, especially if your chiller is installed outdoors.

Checklist:

• Inspect control panels and wiring for moisture intrusion or corrosion.
• Ensure heaters in control boxes or compressors are operational.
• Test safety devices, sensors, and control settings for accuracy.

Routine checks keep your electrical systems reliable even in freezing temperatures.

5. Keep Condensers and Coils Clean

Winter debris such as leaves, dirt, and ice can restrict airflow, forcing your chiller to work harder.

Maintenance Tips:

• Clean air-cooled condensers and verify that fan motors are free of ice buildup.
• Maintain clear airflow around outdoor units by removing obstructions.

This simple step goes a long way in maintaining energy efficiency and preventing system strain.

6. Schedule Preventive Maintenance with G&D Chillers

Proactive maintenance is your best defense against winter downtime. A seasonal service inspection from G&D Chillers or an authorized technician ensures your system is optimized for cold weather operation. Our technicians check everything from refrigerant levels to control calibration—so you can focus on your business with confidence.

Final Thoughts

Winter brings unique challenges for any cooling system, but with proper care, your chiller can operate efficiently all year long. Whether you’re running process cooling for breweries, wineries, dairy operations, data centers, or industrial applications, these preventive steps will help protect your investment and maintain consistent performance.

Need help preparing your chiller for winter?
Reach out to the experts at G&D Chillers today for professional service, maintenance plans, and customized cooling solutions that keep your system running at peak performance—no matter how cold it gets.

Contact G&D Chillers: techsupport@gdchillers.com

A Guide to Safe and Efficient Downtime Procedures

By John McCoy

In the world of industrial cooling, glycol chillers are the backbone of temperature control for breweries, wineries, distilleries, and other process-driven operations. While these systems are designed for continuous use, there are strategic reasons why extended shutdowns can be beneficial, especially during seasonal lulls or planned maintenance windows.

1. Preventative Maintenance Opportunities

Extended shutdowns allow for thorough inspection and servicing of the chiller system. This includes:

• Cleaning heat exchangers and evaporators
• Checking for leaks in glycol lines
• Replacing worn-out components like pumps, valves, and sensors
• Flushing and replacing glycol mixtures if needed

Proactive maintenance during downtime helps prevent unexpected failures during peak production periods.

2. Energy and Cost Savings

If your facility experiences seasonal slowdowns (e.g., post-harvest in wineries or winter months in breweries), shutting down the chiller can lead to significant energy savings. Glycol chillers are high-demand systems, and reducing runtime during off-peak periods can lower utility bills and reduce wear on equipment.

3. System Upgrades and Retrofits

Extended shutdowns provide a window for system upgrades without disrupting operations. Whether you're adding new tanks, expanding capacity, or integrating automation controls, having the chiller offline makes installation safer and more efficient.

4. Environmental and Sustainability Considerations

Reducing unnecessary energy consumption aligns with sustainability goals. Extended shutdowns can be part of a broader strategy to minimize carbon footprint, especially when paired with energy audits and system optimization.

5. Operational Planning and Staff Training

Downtime is a great opportunity to train staff in system operation, safety protocols, and troubleshooting. It also allows teams to review SOPs and prepare for upcoming production cycles with a refreshed understanding of the chiller’s role.

6. Avoiding Glycol Degradation

Glycol mixtures can degrade over time due to oxidation, contamination, or thermal stress. Extended shutdowns allow for testing and replacement of glycol, ensuring optimal heat transfer and freeze protection when the system is restarted.

7. Risks of Refrigerant Migration During Extended Downtime

While extended shutdowns offer many benefits, they can also introduce risks, particularly refrigerant migration. When a glycol chiller is powered down for a long period, refrigerant can migrate from the compressor to other parts of the system, such as the evaporator or suction lines. This can lead to hard starts, liquid slugging, or even damage to critical components when the system is restarted.

To avoid these issues, it's essential to follow G&D Chillers’ recommended shutdown procedures. These steps are designed to:

• Safely isolate and stabilize refrigerant
• Protect the compressor and internal components
• Ensure a smooth, trouble-free startup when operations resume

Proper shutdown planning minimizes the risk of costly repairs and downtime, preserving the integrity and performance of your chiller system.

Conclusion

While glycol chillers are built for reliability and performance, strategic extended shutdowns, when paired with proper procedures, can enhance system longevity, reduce costs, and improve operational efficiency. At G&D Chillers, we support our customers with expert guidance on when and how to safely shut down and restart their systems, ensuring peak performance when it matters most.

We’re here to help 24/7. If you have any further questions, be sure to give us a call or contact us at techsupport@gdchillers.com.