technotrans offers central chillers for water-cooled presses. technotrans expertise and quality brings you peace of mind

1. The Concept for Controlled
Heat Removal from Sheet Fed
Press Auxiliaries

2. Influence of heat on rel. humidity
Waste heat makes the The task: cut heat load in the press room down to
print room temperature the minimum
rise
Increasing air
30°C
temperature (1) causes Why care about heat
30% RH
decreasing rel. humidity management ??
Humidifiers can raise (2)
the rel. humidity back to The rel. humidity
desired value, resulting in has a strong
an adiabatic cooling 25°C impact on paper
effect (except steam 50% RH
condition .….and
humidifiers) therefore on
Overnight temperature productivity !!!
falls (3) resulting in even
higher rel. humidity
Ideal printing 21°C 21°C
climate 55% RH 75% RH

3. Psychrometric chart
Press heat makes the
press room temperature
rise
Increasing air
temperature (1) causes
decreasing rel. humidity
Humidifiers can raise (2)
the rel. humidity back to
desired value, resulting in
an adiabatic cooling effect
(except steam humidifiers)
Overnight temperature
falls (3) resulting in even
higher rel. humidity

4. Rel. humidity and temperature
A day in a print room
without rel. humidity Print Room Climate temperature°C RH % Optimum RH 55%
control Temp. °C RH%
45,0 100
Decreasing air 90
temperature causes 40,0
80
increasing rel. humidity
35,0
70
Increasing air
60
temperature causes 30,0
decreasing rel. humidity 50
25,0
40
MIN RH occurs
30
at MAX temperature 20,0
and vice versa 20
15,0
10
10,0 0 day time h
0 1 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

5. Law of conservation of energy
approx. 50 % conversion approx. 50 % conversion
Why does the print room to heat energy to heat energy
heat up? discharged via press discharged via auxiliaries
Because electrical
energy is converted to
heat when press is in
operation
100 % input
electrical energy

6. Simple exhaust fan
Today, almost every
printer faces problems Exhaust air
with heat, dirt, dust and
noise in his press room.
Powerful air-cooled
peripherals of modern
sheet fed presses exceed
the limits of acceptable
pressroom climate.
Make up air from outside disturbs the press room
temperature and relative humidity

7. Advanced exhaust air system
Exhaust hoods and ducts
prevent hot air released Exhaust air
by the peripherals to mix
with room air.
But missing control on
make up air creates under
pressure in the press
room.
Make up air from outside disturbs the press room
temperature and relative humidity

8. Advanced ventilation / AirCon system
The problem of heat
extraction might be
solved by advanced Make up air Exhaust air
ventilation or complete
air conditioning
systems.

9. Disadvantages of air cooling
High air velocity in the pressroom
Excessive amounts of paper dust and powder in
the air (particles cannot settle)
Difficult to maintain constant rel. humidity and temperature
Higher energy consumption for air conditioning
High demand and costs for maintenance and cleaning
Conclusion:
With high heat loads, air cooling
becomes impractical in technical
and economic terms.

10. Water can....
Be moved easily in a closed loop pipework
Collect the heat load of each connected
auxiliary unit
Remove the heat load from the print room
Provide cooling to several presses
Allow optional heat recovery

11. The principal of water cooling
Cooling water is
circulated in a closed
loop.
No water consumption approx.
30°C
to 48°C Air blast cooler
A suitable external
concentration of 20°C
glycol allows safe to
operation during the 40°C
cold season
(standard 35%)
Peripherals
Pump station
internal

12. Water-cooled peripherals
By centralising the peripherals in cabinets, all press
peripherals can be water-cooled and the generated heat
can be exhausted from the pressroom
Air supply technotrans Dryer
Combination unit

13. Advantages of water-cooling
Reduction of sensible
heat in the pressroom
Using water-cooled auxiliary equipment combined
Decreased air velocity with a central cooling system, can move 50% of the
press generated heat out of the pressroom.
Decreased pollution
and noise
Easier air temperature /
rel. humidity control in
the pressroom
Spare capacities for
future needs can be
considered

14. Air versus water-cooling
Example: Important characteristics:
Comparison: Air Water + Glycol
6 printing units + coating, Specific. heat capacity: 1 3.7
format 70 x 100 Density: 1.2 800
- fount solution circulator
- ink roller temperature
15
0
control
kW / h
20
- air supply cabinet
m
3
- UV curing 200 W/cm
3x end of press Cooling water pipe
1x interdeck 65mm
Total cooling capacity
required: 150 kW
15 0.0
0 00
4
kW m
h3
Air duct 1200 mm

15. Design criteria for water-cooling
The choice for technology
depends mainly on two
criteria:
The local climatic
conditions i. e. max.
summer outside
temperature and rel.
humidity
The required cooling
water temperature (in
general between
10°C / 50°F and 40°C /
104°F)

16. Free cooling with airblast cooler
The air blast (dry) cooler Air blast cooler
transfers heat directly to outdoor installation
the ambient air whilst the
pump system
automatically controls the
heat discharge.
Suitable up to 35°C/95°F
ambient air temp. (special
design up to 38°C/100°F).
Optional “adiabatic”
booster allows operation Pump system
indoor installation
at 40°C/104°F.

17. Free cooling with adiabatic booster
All cooling technologies The limits for air blast (dry) cooling are reached when outdoor
are limited to certain air temperatures exceed 38°C/100°F.
outdoor temperatures. A chiller is the typical way to overcome this limitation increasing
the el. power consumption by more than 250%!
The most cost-effective In most countries ambient air temperatures peaks occur for a
solution for ambient few hours on summer days only. During these hours, only on
temperatures exceeding demand, the free cooler is sprayed with water, generating a
35° /95°C is the optional fine mist. While the sprayed water evaporates, the water
adiabatic booster. temperature in the the cooler drops.The cooler fins are
protected by a special coating to prevent electrochemical
corrosion.
As soon as the outdoor air temperature drops, the water-cooling
system is operated as a typical free cooling system without water
demand (dry mode).

18. Free cooling with adiabatic booster
The adiabatic booster Principle of the “swamp cooler”
extends the range of
operation temperature
for air blast coolers
Great advantage:
Attractive price
Very reliable technology
Low power demand

19. Free cooling with adiabatic booster
Example for adiabatic
The temperature drop
cooling by moistening the
depends on the
air with water
difference between old
relative humidity and new
IN -> OUT
relative humidity, while
40.0 / 40% -> 35.0°C/60 %
the amount of water
needed for the cooling
process depends on the
airflow moistened.

20. Free cooling with adiabatic booster
Site requirements
Spray water consumption:
depending on:
- required cooling capacity,
- temperature & rel. humidity outside air
Spray water pressure requirements:
- min 2.5 bar (higher is better)
- Water hardness: 2 - 4 dH
(to prevent lime on spray nozzles and cooler fins)
Depending on the local water quality, a water softener
might be necessary
(can be provided by technotrans)

21. Pump module for integration in beta.c G
Pump module
Alternative to separate
pump station cabinet
Glycol cooler
Great advantages:
Great cost saving
Space saving (no cabinet !)
Pump
Automatic controller module
shared with beta.c G unit
Dryer
Simplifies piping on site Air
TH/IR
Supply
UV
Note:
Different models for beta.c modular
and old style beta.c
optional beta.c G

22. Turn-key installations
Turn-key installations ... what we need:
by technotrans: To-scale print shop layout providing position of:
Individually engineered - water-cooled cabinets
for each project - cooler and pump station
- height of ceiling
h

23. Scope of delivery
Schematic layout for
installation:
Individually engineered
for each project
Delivered with each
cooling system for
installation by
contractors
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24. Turn-key installations
Coolers:
Mounted:
- on roof top
- on ground
- on wall
- horizontally

25. Turn-key installations
Cabinet connection:
- rubber bellow
- flexible hose

26. Turn-key installations
Pipe Material:
- black steel
- copper
- stainless steel
- polypropylene
- C PVC

27. Comparison of investment costs
Air conditioning is the
most expensive way to
control the press room
100%
temperature 90%
80%
70%
Exhaust air systems are 60%
the cheapest solution 50%
40%
Print shops produce all 30%
year long and the real 20%
expenses naturally come 10%
up during operation 0%
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This comparison is based on average European prices.

28. Operation costs
The reason for the To get an idea about savings and profit, the operation costs
obvious difference in must be considered.
costs is the fact that
water-cooling replaces
the peripherals exhaust 25.000
air
20.000
Exhaust air systems
cause the highest 15.000 humidification
water
operation costs
fuel
10.000
electricity
Water-cooling pays off 5.000
quickly
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29. Experience, liability and service
Experienced in cooling technotrans has delivered over 1000 water cooling systems,
systems serving web providing suitable production climate in print shops all over
offset over decades, the world
technotrans provides
reliable cooling
technology for
sheetfed offset for
more than five years.
Consult us:
For the best and most cost
effective solution for your
pressroom.