45 kW Chiller for an Offset Printing Facility in Denmark

A global publisher from Denmark with international standards

New Era Publications International ApS is based in Copenhagen and has been producing and distributing a variety of intellectual products for readers around the world for more than five decades. The company publishes print and audio formats in dozens of languages, supplying Europe, the UK, the CIS, India and the Middle East. High print runs and a variety of formats require marvellous technological discipline and a stable printing infrastructure.

Production facilities are located in Denmark, one of the most mature and digitalised jurisdictions in Europe. Here, quality and energy efficiency standards are clearly regulated and business planning is based on predictable regulations.

In such an environment, any disruption to the print cycle becomes critical to meeting delivery schedules and other contractual obligations. The Danish print industry is under pressure: the export market for commercial printing is gradually shrinking, the share of digital channels is growing, and competition for customers and human resources is intensifying. This makes operational costs, equipment energy efficiency and minimising downtime important economic factors for printers.

For New Era Publications, process continuity is a strategic objective. In offset printing, the stability of the humidifying solution and shop climate determines the quality of exported products. Temperature, humidity and water management affect not only image reproduction, but also the accuracy of paper geometry, machine speed, material consumption and the level of potential scrap. Therefore, an engineered cooling infrastructure becomes part of a company’s competitive advantage: it is not a support circuit, but a mechanism to protect product quality, speed of order fulfilment and brand reputation in international markets. When every degree of temperature and percentage of humidity has a direct impact on paper geometry, register accuracy and colour balance stability, a properly selected and tested chiller saves on scrap, reduces downtime, keeps equipment utilisation high and allows the print shop to confidently accept larger and more urgent runs while maintaining quality levels. It’s a strategic investment that pays off not with promises, but with concrete parameters that remain consistent every hour, every shift, every day.

Parameters and production requirements for an HVAC system

The offset process only works under strict environmental control: temperature, humidity and water quality directly determine register, sheet geometry and ink behaviour in the print zone.

The main circuit is the cooling of the moisturising solution. It maintains the ink-water balance, stabilises the plate surface and prevents the paper from drying out at high speeds.

Temperature stability and quality of the moisturising solution:

The operating temperature of the wetting solution is 10-15 °C with an allowable difference of ±0.3 °C, where deviations of -1.5 °C cause condensation on the cylinders and unstable emulsification:

– An accuracy of ±0.3 °C – a deviation of only ~2% of the range is already reflected in the exportable quality of the feed product;

– Less than 10 °C (-1.5 °C) – condensation on the platemaking cylinders, unstable emulsification and thinning of the ink layers;

– Above 15 °C (1.2 °C) – the paper starts to accept excessive water, the balance of moistening and ink fixation on the plates is disturbed;

– Cooling load – requires ~1.1 kW for each tonne of mortar circulation at a flow rate of 4-8 T/h for typical machines.

Print room microclimate for high register accuracy:

Regulatory point 22 °C and 55% RH – a 5% reduction in humidity causes sheet deformation of up to 0.05-0.1 mm per metre length, for 720×1020 mm this is already in the order of 0.1 mm print pattern offset:

– Reducing the humidity by 5% RH causes paper shrinkage and geometry changes of up to 0.05-0.1 mm per m³ of path;

– For a 720×1020 mm format, such a change leads to ~0.1 mm of register shift, which reaches the technological threshold of rejection;

– An increase in air temperature of only 1.8 °C lengthens the ink setting time by 12-18%, which increases the risk of fouling and smudging.

Chemical-physical control and hydraulic efficiency:

Water retention in the process window: pH 4.8-5.5; hardness 6-12 °dH; conductivity around 900 μS/sm – no out of limits.

Chemistry and hydraulics in offset printing efficiency calculations:

– A 2 °dH increase in water hardness reduces the heat transfer coefficient in a plate heat exchanger by about 4-6%;

– A ±0.4 pH deviation significantly affects the chemical balance of the dampening solution and increases the number of print rejects;

– Tolerance of flow rate pulsations not more than 3% – at a flow rate of 4-8 T/h it is ±0.12-0.24 T/h, which ensures stable temperature maintenance;

– Hydraulic head of 18-22 m water consistently provides ~1.1 kW/T circulation heat dissipation and eliminates mould cavitation.

Partial load and noise characteristics of HVAC system:

Print shops rarely operate at full capacity: 60-80% of the time equipment is operated at partial plant load:

– The air-cooled chiller remains efficient at 30-40% of heat load, maintaining ΔT ±0.3 °C and a regular flow of 4-8 T/h;

– Fan noise of 58-62 dB(A) at 10 m in accordance with noise insulation and sound acoustics standards and requirements in the northern European region;

– Compliance with parameters reduces up to 90% of defects; Sheet geometry held ±0.1 mm; Ink fixation on seals ±12-18%.

Engineering precision cooling has a direct impact on print quality, run stability and production economics: keeping paper geometry and ink balancing at high speed minimises rejects and provides a competitive advantage for the print shop in this aspect.

Energy-efficient solution for controlling the printing process

The print shop required a cooling unit with a capacity of 45 kW. The EF COOLING WKL 390 EVO 45 was chosen for its quick start-up and minimal commissioning. The unit is optimised for offset presses, supports print runs of 500-1,500 sheets per hour and is compatible with water and wetting solution cooling systems up to 8 tonnes per hour, ensuring stable temperature control and process accuracy in the print shop areas.

The equipment has a rated heat load of 45,000 W and a heat dissipation rate of up to 1.2 kW per tonne of solution circulation at volumes of 4-8 tonnes per hour, allowing ΔT to be quickly brought to stabilisation. The operating range of the humidifying solution is 10-15 °C, ΔT stability is maintained at ±0.3 °C and corresponds to fluctuations of no more than 2% of the range minimising the risk of condensation.

The configuration of the unit includes 2 Panasonic scroll compressors of 22.5 kW each, an 8.4 m² plate heat exchanger with a heat transfer coefficient k = 360 V/m²/K, 2 fans with a total airflow of 2 × 3 200 m³/h and a noise level of 60-62 dB at 10 m, as well as an integrated hydronic module with a head of 18-22 metres of water column and a flow pulsation of less than 3%, ensuring precise temperature maintenance and a stable cooling cycle at partial loads.

The benefits for the print shop are temperature and humidity maintenance at partial loads of 30-40%, energy savings of up to 12% and a 5.4 kW reduction in consumption with the chiller running 24 hours a day. The circuit of printing units and auxiliary systems is completely closed: the temperature of the humidifying solution is stabilised at 12-14 °C, humidity is kept at 54-56 % RH, and the reaction time to load changes does not exceed 30 seconds, which allows paper geometry and colour accuracy to be maintained without a single defect.

Technical innovation and HVAC precision with EVROPROM

The first project with a new customer EVROPROM built a fully transparent and controlled process. The equipment was accurately and comprehensively tested at the in-house test station, with detailed reports and video recording of all 12 key operating parameters, including humidifying solution temperature of 10-15 °C, relative humidity of 55 % RH and ΔT ±0.3 °C at 30-40 % loads. Each Panasonic 22.5 kW scroll compressor, 3,200 m³h fans and an integrated hydronic module with 18-22 m water column head were tested in 24/7 continuous operation to ensure consistent runs of 500-1,500 sheets/h and temperature maintenance on all 8 tonnes of circulating solution.

A 2-part payment scheme minimises financial risks and direct delivery from a European warehouse reduces logistics time to 3-5 days. EF COOLING WKL 390 EVO 45 offers energy savings of up to 12 %, which with an industrial tariff of 0.20 €/kW/h and 8,000 hours of operation per year results in savings of around 86,400 €. Temperature and humidity control reduces rejects by up to 90% and maintains a paper geometry of ±0.1 mm, ensuring accurate colour reproduction even under partial loads.

Process optimisation with total precision and safety

EF COOLING WKL 390 EVO 45 combines precise climate control with full integration into the print shop’s process loop: the temperature of the humidifying solution is kept at 10-15 °C with a tolerance of ±0.3 °C, the air humidity is stabilised at 55 % RH and the reaction time to load surges is less than 30 seconds – all of which minimises the risk of condensation, paper shifting and colour defects. The unit withstands partial loads of 30-40% of nominal, heat dissipation of 1.1 kW per tonne of solution at 4-8 T/h and provides energy savings of up to 12% in commercial operation, while the integrated hydronic module with a head of 18-22 m water column and flow pulsation of less than 3% simplifies commissioning and reduces the burden on the HVAC service.

In addition, the EF COOLING WKL 390 EVO 45 provides: consistent quality at line speeds of 500-1,500 sheets/h, adaptation to Nordic market noise standards of ≤62 dB per 10 m, pH and water hardness of 4.8-5.5 / 6-12 °dH, integration with water and solution cooling systems for humidification up to 8 T/h and complete closure of the printing circuit.

Quality, efficiency and economy with EVROPROM

With EVROPROM, each chiller is tailored to the specific process parameters: stable range of 10-15 °C, precise humidity retention of 54-56 % RH, operation at partial loads of 30-40 % of rated capacity and support for heat loads up to 45 kW.

The aim is to ensure perfect print quality and continuity for runs of 500-1,500 sheets per hour, where every degree and every drop of moisture has a direct impact on the result: -1.5 °C leads to condensation on the platemaking cylinders, 1.2 °C causes increased ink water absorption and streaking.

EVROPROM guarantees full control and service at the base:

– Testing of the chiller at our own station: 8 parameters, video protocol, measurement report; check of the heat load of 45,000 W and the humidifying solution flow rate of 4-8 T/h;

– Deliveries from Europe in 3-7 days including customs, European taxes and full documentation;

– Compliance with North European noise regulations ≤70 dB(A) at 10 m and accurate ΔT ±0.3 °C;

– Optimisation of total cost of ownership: compressor and fan speed control results in energy savings of 12-18 %;

– Packing and technical list: all components, quantities and parameters are recorded, each pallet and carton is labelled for accurate receipt at the warehouse and at the customer;

– Pre-loading service: checking the operation of all components, flushing heat exchangers and hydromodule, checking the tightness of pipework, testing compressors and fans; ensures that the equipment is fully ready for installation and operation.

– Testing and control: 8 key parameters (temperature, ΔT, flow, head, humidity, noise, tightness, stability at 30-40% load), video protocol and measurement report;

– Lead time: 1-2 working days per station and up to 24 hours for packing and inspection before shipment.

With EVROPROM, the production circuit becomes a predictable and controllable system: stable temperature and humidity maintain paper geometry and colour accuracy, reducing rejects by up to 90%, and each shift and each print run is accurate to ±0.05-0.1 mm, even at speeds of 500-1,500 sheets per hour. The equipment is fully tested under real conditions and runs continuously, making the chiller a strategic tool for quality and efficiency.

Article author:

Svyatoslav Ovcharenko, Sales Manager

28.10.2025