Winter Glycol Checks – As temperatures drop, industrial cooling systems face greater risk from freezing, corrosion and bacterial growth. A simple glycol check is one of the most effective ways to avoid winter breakdowns and keep production running smoothly. Below are key steps every processor should follow to ensure their chiller plant is fully protected for the colder months.
1. Confirm your glycol concentration
The most important task is to verify that glycol levels fall within the recommended range for UK conditions. A concentration of 25% to 30% is typically required to achieve freeze protection from approximately minus 12°C to minus 16°C. Anything below this increases the risk of freezing and encourages bacterial growth.
2. Check for dilution or contamination
Systems that have been topped up regularly may have a lower concentration than expected. Water ingress, corrosion products or bacterial contamination can all reduce freeze protection and affect thermal performance. Test the fluid for clarity, colour and odour and look for any signs of suspended particles. Summit Process Cooling can carry out a quick on-site analysis to confirm fluid quality.
3. Inspect strainers, filters and pipework
Strainers and filters often capture debris, rust flakes and organic matter that can build up over time. Before winter, clean or replace these elements to maintain proper flow and prevent blockages. It is also worth checking pipework for corrosion or leaks that may have caused previous dilution.
4. Validate freeze point protection
Even if concentration appears correct, it is important to confirm the actual freeze point. Different glycol types and inhibitors can influence freeze performance. A handheld refractometer or test kit can quickly verify the true protection level. Summit Process Cooling engineers can validate this for you and advise on corrective actions if needed.
5. Review the type of glycol in use
Ensure your system is filled with the correct fluid. Mono Ethylene Glycol (MEG) offers excellent heat transfer, while Propylene Glycol (PG) is preferred for lower toxicity environments. DTX glycol provides a non-toxic alternative with strong inhibitor performance. Using the wrong product or mixing types can reduce protection and shorten fluid life.
6. Top up with the correct inhibited glycol
If levels need adjusting, top up only with the same glycol type and ensure it includes a corrosion inhibitor package. This helps protect pumps, heat exchangers and mixed metals within the system. Summit Process Cooling supplies MEG, PG and DTX glycol in 25 litres to 1000 litres drums for easy, controlled top-ups.
7. Look for signs of bacterial activity
If glycol concentration has slipped below 20% at any point, bacteria may already be present. Symptoms include discolouration, cloudy fluid, odour, black sludge or reduced flow. Early detection prevents fouling and blockages that can cripple cooling circuits in cold weather.
8. Book a professional glycol test
For complete peace of mind, schedule a winter glycol check with Summit Process Cooling. Our engineers will test concentration, freeze point, inhibitor performance and general system condition, then provide clear recommendations to ensure your cooling system stays protected all winter.