Optimizing Glycol Chiller Performance During Off-Peak Periods

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.