How To Improve Chiller Efficiency? Included Chiller Efficiency Formula

Still Frustrated by Low Chiller Efficiency? If your chiller isn’t performing as efficiently as you’d like, you’re not alone. This blog post dives into practical strategies for improving your chiller’s performance. Keep reading to discover smart, effective solutions that can boost efficiency and reduce operating costs.

Understanding Chiller Efficiency in 2025: What’s Changed?

With the rapid advancement of industrialization, companies across various sectors are continually striving for higher production efficiency and superior product quality to stay competitive in the market. In this context, chillers have become increasingly important as critical support equipment in modern industrial processes.

Expectations for chiller performance have risen significantly. Today, businesses not only require chillers to meet basic cooling needs, but also demand greater stability and enhanced energy efficiency. Chiller efficiency has become one of the core metrics for evaluating overall performance. It is a key factor in determining whether the equipment can deliver meaningful value in real-world applications.

From both technical and economic perspectives, the efficient operation of chillers has a direct impact on production costs and overall competitiveness. As a result, how to improve chiller efficiency has emerged as a major area of focus within the industry.

Il Chiller Efficiency Formula Explained

The standard chiller efficiency formula is:

Chiller Efficiency (kW/ton) = Power Input (kW) / Cooling Output (tons)

The lower the kW/ton, the more efficient the chiller.

7 Ways To Improve Your Chiller Efficiency

The following tips can help you improve chiller efficiency:

Monitor and Optimize Operating Conditions

Before operating a chiller, it is essential to verify that all system parameters fall within appropriate ranges.

The refrigerant charge must be precisely adjusted based on the specific operating conditions to stay within the recommended limits. Both overcharging and undercharging can negatively impact the chiller’s performance. Additionally, it is advisable to prioritize the use of environmentally friendly refrigerants with low Global Warming Potential (GWP).

These not only reduce environmental impact but also help comply with increasingly stringent regulatory standards.

Controlling chilled water flow is a key aspect of optimizing system performance. During actual operation, the flow rate should meet design specifications to prevent energy waste or potential damage to the chiller due to insufficient or excessive flow. Installing intelligent flow control devices can help by continuously monitoring and adjusting flow in real time, allowing for more precise system management.

In general, the lower the cooling water temperature, the higher the chiller’s efficiency. However, excessively low temperatures may result in unnecessary energy consumption. Therefore, it is important to find a balanced setpoint. By optimizing cooling water temperature settings, both cooling performance and operational costs can be improved.

 

Keep Heat Exchange Surfaces Clean

After extended periods of continuous operation, chillers often accumulate scale, dirt, and other impurities on the surfaces of the condenser and evaporator tubing. If these deposits are not cleaned regularly, they will build up over time, significantly reducing heat exchange efficiency. As a result, the overall performance of the chiller will decline, making it difficult to meet the expected cooling demands. Furthermore, operating under such suboptimal conditions can lead to increased wear on internal components, ultimately shortening the lifespan of the equipment.

In circolatore refrigerato systems, tap water is commonly used as the primary source of cooling water. To ensure proper system operation and extend the lifespan of equipment, water treatment must be given serious attention. This is because tap water may contain various impurities and minerals. If not properly treated before entering the circulation system, it can lead to issues such as pipe blockages, equipment corrosion, and reduced heat exchange efficiency.

For example, by using filtration, softening, or chemical treatment methods, the concentration of suspended solids, calcium and magnesium ions, and other harmful substances can be reduced. This helps prevent scale buildup and sediment formation, ensuring the refrigeration system operates efficiently and reliably.

 

Operate at Part Load Efficiently

In actual operation, chillers rarely run at full load continuously. Most of the time, the system operates below its maximum capacity, which can lead to reduced energy efficiency. To address this common scenario and improve overall energy performance, it is advisable to equip key components of the chiller—such as the compressor, water pump, and fan—with variable frequency drives (VFDs). This allows the equipment to dynamically adjust operating speed and power output based on real-time demand, resulting in more energy-efficient and cost-effective performance.

 

Implement Smart Controls and Automation

If your current chiller lacks intelligent control capabilities, consider integrating it into a Building Management System (BMS) or a centralized control platform. This integration allows for automated start-stop operations and precise load adjustments, which can enhance operational efficiency and reduce energy consumption. Additionally, noise issues associated with chiller operation can often be mitigated by optimizing the control system.

For example, as early as 2021, LNEYA refrigeratori adopted the Siemens PLM+UG+AD automation system to enhance performance and control.

Looking ahead, it is recommended that, starting in 2025 and beyond, predictive maintenance systems powered by artificial intelligence be introduced. These systems leverage advanced algorithms and data analytics to monitor key operating parameters in real time and use historical data and trends to forecast potential failures—enabling proactive maintenance and minimizing downtime.

 

Measure, Benchmark, and Improve

During chiller operation, advanced monitoring systems can be used to track and record key performance indicators in real time, such as kilowatts per refrigeration ton (kW/RT), coefficient of performance (COP), and overall energy consumption. Collecting this data provides a comprehensive view of the system’s current operating status. By comparing real-time data with historical performance records, you can more accurately assess whether the chiller’s efficiency is declining.

Additionally, it is highly recommended to conduct regular, comprehensive energy audits. These audits not only evaluate the chiller’s total energy consumption, but also help identify hidden energy-saving opportunities embedded in day-to-day operations.

 

Perform Seasonal Performance Tuning

After a period of operation, chillers require regular inspection and maintenance. For this, you can contact the chiller manufacturer to perform seasonal tune-ups and ensure optimal system performance.

Technical personnel from the chiller manufacturers typically carry out periodic upgrades and performance optimizations. When new system versions become available, they will notify you to help keep your equipment running at its best. It’s a good idea to stay informed about updates and developments from your chiller manufacturer.

 

Retrofit Or Upgrade Where Necessary

Older chillers often suffer from reduced efficiency and may no longer meet the cooling demands of modern industrial applications. To improve performance, you might consider retrofitting the system with variable frequency drives (VFDs), high-efficiency motors, or variable-speed compressors.

If the return on investment is favorable, it is recommended to replace outdated units with a high-efficiency, environmentally friendly chiller—such as those offered by LNEYA—for better long-term performance and sustainability.

Final Thoughts: Make Full Use Of Your Chiller

LNEYA has specialized in low-temperature thermal control for over 15 years. Guided by a commitment to customer-first and quality-first principles, LNEYA is dedicated to delivering competitive system solutions and services that consistently create greater value for you.

Choosing LNEYA means choosing a more efficient chiller—and a smarter path to performance and reliability.