How to Use Your Chiller System More Efficiently in 2025:A Guide to Optimal Performance

Many industries and applications rely on water chillers to provide cooling in the processes. However, these chiller systems use a lot of electricity, accounting for a large portion of energy use. In this article, we will explore how you can increase the efficiency of your water and air cooled chiller in 2025, starting with understanding the chiller system efficiency formula.

Why Optimal Chiller Efficiency Matters for Your Process

Improving chiller system efficiency can save more money on electricity and reduce energy waste, which in turn helps lower carbon emissions.

Therefore, reducing the energy consumption of your water chiller benefits the environment by lowering greenhouse gas emissions and other pollutants. In addition, companies that can effectively use water chillers can gain a competitive advantage by reducing their production costs. This can ultimately help them become more profitable and sustainable in the long run.

How to Calculate Your Chiller System Efficiency

Understanding the Chiller System Efficiency Formula:

Calculating chiller system efficiency refers to the formula based on the Coefficient of Performance (COP) , which is defined as the ratio of the cooling output to the energy input. The formula is expressed as COP = Cooling Output / Energy Input (Both values are expressed in kilowatts (kW). By calculating the COP of your chiller, you can assess its efficiency and identify areas for improvement.

For example, if your water chiller produces 100 kW of cooling while consuming 20 kW of electrical energy, its COP will be:

100 kW / 20 kW = 5

This means that the industrial chiller produces 5 kW of cooling for every 1 kW of electricity consumed.

For the calculation, you first have to convert BTU to kW. If your chiller’s total cooling is measured in BTU/Ton or Kcal/h, you first have to convert them to kW before using this chiller efficiency formula.

5 Ways To Improve Chiller System Efficiency

1.Regular Maintenance

Keep a record of the chiller system’s condition so you can easily detect any common chiller problems with the system. This will allow you to schedule routine chiller maintenance to ensure that the unit operates at peak efficiency and reduces the likelihood of a breakdown.

A few examples of regular maintenance include:

Inspect and clean condenser coils regularly

Check refrigerant levels and refill if needed

Monitor and replace air or water filters

Verify pump operation and inspect for leaks

Test electrical connections and control panels

It is preferable to have a qualified technician perform the chiller repairs and preventative maintenance, particularly for tasks requiring technical knowledge, such as refrigerant handling.

2.Optimal Set Points

Adjusting the set points of your industrial chiller based on seasonal requirements can help reduce energy consumption. Implementing a setback strategy during off-peak hours can further enhance efficiency.

3. Maintain Proper Refrigerant Levels

We mentioned refrigerant checks in routine maintenance — now let’s break down why keeping proper refrigerant levels is so important.

The efficiency of a chiller system is closely related to how well the compressor can pump the refrigerant through the system. As a result, maintaining proper chiller refrigerant levels is critical to ensuring the compressor’s efficiency. Leaks are the primary cause of low refrigerant levels. So, make sure to monitor changes in refrigerant levels so that you can detect leaks.

4.Don’t Neglect Fluid(Water) Quality

You need clean and monitor the condenser and evaporator coil when chiller units run for one month or less .Impurities, scale, or debris can build up on condenser and evaporator coils, reducing heat transfer and forcing the chiller system to work harder.

You should regularly test and treat the fluid to prevent corrosion, scaling, and biological growth. Use filtration systems to remove particles, and for water-cooled systems, add anti-scaling agents or biocides as needed. For glycol-based systems, monitor the concentration and replace degraded fluid to avoid damage.

Clean, properly treated fluid helps maintain efficient heat transfer and keeps the water chiller running reliably.

5. Add a Variable Speed Drive (VSD)

Chiller motors are usually the largest single electrical load in a building. Most constant-speed compressors match capacity to load by using inlet vanes, which restrict the amount of gas that enters the compressor impellers.

However, this method isn’t very efficient at modulating chiller capacity. You can use variable speed drives(VSD) to increase energy savings in the chiller system. They reduce the inrush current of the motor to nearly the same level as the amps used when operating at full capacity.

In 2025, maximizing chiller system efficiency is not only a smart business decision but also a crucial step towards environmental sustainability. Upgrade to our dependable air-cooled and water-cooled chillers, designed to maintain ideal temperatures for your process and machinery while maximizing energy efficiency.

Feel free to contact us today for more information about our high-efficiency chillers!