Film fill can be categorized in three basic fill types, high efficiency/ cross corrugated, offset flute and vertical flute/low fouling fills. Each has its own characteristics and when properly matched to the site and water quality conditions can provide many years of low maintenance operations for your cooling tower. Please call for a personalized consultation if you are not certain which fill type is best suited for your tower. Other than just replacement, of existing packs, ICS can assist you with options which may help you upgrade your tower performance or help you reduce maintenance and chemical costs caused by improper fill selections.
Also known as cross corrugated fill, this is the highest performance film fill available with excellent water re-distribution properties. This fill allows for maximum performance in the smallest area and may allow you to upgrade your tower performance if you have good water conditions. Normal flute size is 19 mm.
Offset flute fill is a hybrid between the cross fluted high efficiency fill and the fertical fluted low foul fill. As such it offers the best of both worlds with a high relative performance combined with lower fouling risk. This is the right fill for you if you are trying to maximize performance but know your water quality can be risky for high efficiency fill or if your water treatment is not consistent. Standard flute size is 21mm.
Vertical Flute/Low Fouling
Low fouling fill is the lowest performance film fill but is also the most tolerant to contaminants such as high suspended solids, oils & fats or scaling and micro biological elements. It is often used for seawater applications. Standard flute sizes are 19mm and 38 mm.
SITE ASSEMBLY OF FILM FILL
Replacement of film fill at locations far from the factory may best be served by shipping the fill sheets unassembled to reduce massive freight costs. If buying nested sheets, you must assemble the fill at the site. ICS qualified technicians can assemble the fill at the site for you or supervise your crew in doing the assembly. There are two basic methods of assembling the fill materials & each has its own advantages.
Glue assembly is actually a chemical weld performed when the contact points of the sheets are coated with a mixture of toluene and MEK and then pressed into a curing box to allow the chemical reaction to bond the sheets. This is best done on sites where the climate is moderate and relatively controlled as the “glue” can be hard to manage when the conditions are too variable.
A patented snap together assembly is available which requires no glue is also available. Although more expensive at first cost, the reduced time required for assembly combined with no costly glues to buy, this is an excellent choice for most sites. Additionally, it is faster to assemble, no curing time is required and it is considered environmentally friendly since there are no chemicals required to be brought to your site.