Hydratech Introduce Revolutionary Coolant to US Brewing Industry

For many years, monopropylene glycol (propylene glycol, MPG) has been the go-to heat transfer fluid for use in food and beverage cooling systems. Characteristically, propylene glycol-based coolants have a much lower capacity for efficient heat transfer, compared to the better performing, but toxic ethylene glycol mixes. Propylene glycol is also much more viscous than ethylene glycol at low temperatures, providing more of a challenge to pump.

In 2010, Hydratech revolutionized the European food and beverage industry with the launch of Coolflow DTX. Utilizing American technology, the revolutionary heat transfer fluid exploits the advantages ethylene glycol has over propylene glycol, whilst delivering a non-toxic solution.

Benefits include, more efficient heat transfer, reduced energy consumption, easier to pump (especially at low temperatures), less volume for the same freeze protection, and cheaper per litre (compared to PG). Coolflow DTX is readily biodegradable (90% over ten days) and will not remain in the environment or bioaccumulate.

For brewers previously or currently using propylene glycol-based solutions, DTX technology represents a major improvement in the Coefficient of Performance (CoP). The list of blue-chip users taking advantage of DTX technology is extensive and continues to grow.

‘The big brewery in Ellon runs on DTX and when the time comes to swap the glycol out of the original brewery, we’ll be swapping that as well. It’s been a really good product for us.’ Niall Murphie, Chief Engineer, BrewDog

Here 7 reasons why brewers are making the switch to DTX:

1. Reduced energy consumption As previously mentioned Coolflow DTX has very similar heat transfer and pumping characteristics to ethylene glycol. Comprehensive testing by Star Technical Services verified that DTX reduced energy costs by over 10% (tests were based on relatively low 2015 energy costs, so making a switch to DTX is even more favourable when factoring in today’s energy prices).

Customers have reported improved performance and efficiency gains, alongside considerable energy/cost/CO2 savings after retrofitting existing systems – moving from propylene glycol to DTX. Arla Foods has seen a 17% reduction in energy consumed by the main coolant circulation pumps and process cooling systems after moving to Coolflow DTX.

2. More cost effective per gallon than propylene glycol Propylene glycol prices have fluctuated dramatically over the last 3 years. Contributing factors included extreme weather conditions, a global pandemic, and logistical chaos. While propylene glycol prices have stabilised in recent months, sharp price rises have been reported in the US, following constant demand from the end-user pharmaceutical, food and cosmetic sectors. Cost saving benefits of dosing a new or existing system (retrofit) with DTX are particularly favourable in the current economic climate. For example – given the current rates – a potential saving of over 50% could be made if DTX replaced propylene glycol in a proposed 5,300 Gallon system (protected to 5°F).

3. Reducing capital expenditure cost (CAPEX) at concept design phase As well as utilising the performance benefits of Coolflow DTX, customers have designed their cooling systems with Coolflow DTX in mind, allowing them to make considerable savings in hardware and capital expenditure.

Where DTX is specified at the design stage, savings can be achieved through downsizing of: • Primary gas compressors • Heat exchangers • Circulation pumps & motors • Pipework diameter and length

The smaller systems and plant footprints onsite also provide significant operating cost and energy savings.

4. Endorsed by market leaders The list of Coolflow DTX adopters is extensive and includes a host of well-known craft brewing companies, as well as global brands such as Heineken, Molson Coors, PepsiCo, and Coca-Cola. DTX based coolants are also used in a variety of industrial and commercial sectors, where non-toxicity and low environmental impact are high priorities. End users and contractors from these sectors include, Honeywell Aerospace, Aggreko (Temperature Control Division), Daikin, BMW, Siemens, Mercedes, GE Aviation and AMEC.

5. Core cost reductions As well as the reduction in energy consumed, customers have also reported a noticeable reduction in running time and load on their primary refrigerant compressors, which they believe will considerably prolong the life span of their system.

Other cost reductions are achieved by: • Increasing speed of heat transfer and production process • Improving Coefficients of Performance • Minimising compressor loading and running hours

6. DTX – 15 years of industry proven success For over 25 years, Hydratech have been assisting the food and beverage industry with fluid selection and management – utilizing over 120 years combined experience in all aspects of cooling and heating applications.

Coolflow DTX has been specified and installed in thousands of RAC, HVAC and glycol chiller systems, including; process cooling, blast freezing, refrigeration and air conditioning applications. For over 15 years, leading refrigeration specialists such as J&E Hall, GEA and Star Refrigeration have been utilizing the operating benefits of DTX, to improve chilled water (CHW) system efficiency, save energy and minimise unplanned maintenance.

7. Comprehensive protection against corrosion, scale, and biological fouling Preventing corrosion and bacterial contamination in chilled water systems is essential if operating efficiency is to be maximised, and costly maintenance issues are to be minimised. It would be easy to assume all glycol-based antifreeze solutions provide the same fluid and system protection, however, that is not the case.

Coolflow DTX is formulated with multi-metal and multi-function inhibitors, which exceed ASTM & BS corrosion standards. The formulation provides comprehensive long-term protection against corrosion, scaling, and biological fouling, helping to improve chiller efficiency, reduce maintenance and extend chiller system life.

Since 1998, Hydratech have specialised in the formulation and manufacture of high-performance heat transfer fluids, based on glycols, brines, alcohols and refined vegetable extracts. In 2022, Hydratech celebrated the opening of their first U.S. site in East Granby, Connecticut.