Choosing the right fill material is one of the most important decisions you’ll make to keep your cooling tower running smoothly. Whether you’re operating a cooling tower in an industrial plant, a refinery, or even a large office building, the right fill can significantly improve efficiency, energy use, and long-term maintenance.

What Is a Cooling Tower Fill?

Cooling tower fill is the material inside the tower that helps water cool down. It works by giving the water more surface area to spread out and come in contact with the air. There are two main types of fill:

• Splash Fill: This type breaks water into small droplets, increasing the surface area exposed to air. It is useful for handling dirty or poor-quality water because the droplet formation helps prevent debris buildup, keeping the system running smoothly.
  
• Film Fill: This type spreads water out in thin sheets across the fill surface, allowing more contact with air. It’s highly efficient for cooling clean water, but it can be prone to clogging if debris is present.
  

Why the Right Fill Material Matters

If the fill isn’t suitable for your system, your tower won’t cool the water as efficiently as it should. This can lead to higher energy costs because the system has to work harder to achieve the same result. It can also

• Improve water flow to keep things running smoothly
• Reduce fouling and scaling, which reduces the over cost of cleaning and repairs
• Extend the life of your cooling tower by avoiding extra wear and tear on its components

Choosing the right fill isn’t just a technical detail. It’s a long-term investment in the efficiency and reliability of your cooling tower. 

What to Consider When Choosing Fill Material

What works for one cooling tower might not work for another. Here are some things you should keep in mind when selecting the right fill for your system.

Cooling Technology Institute (CTI) Standards. Ensure the fill meets CTI certification for performance and durability in cooling towers. For example, for thermal certification, a cooling tower must have a thermal capacity equal to 100% of its listed rating during testing.

Regional Standards. Some regions may require you to follow specialized standards against bacterial growth, such as the ASHRAE Standard 188 for Legionella prevention.

Environmental Protection Agency (EPA) Regulations. Make sure your chosen fill material helps your system comply with regional and EPA water use and discharge regulations for your industry.

Fire Retardant Standards. Fill materials can be made from various materials, including wood and PVC. Some industries are required to ensure that fill materials meet local fire safety codes or UL fire retardant ratings.

Durability. Make sure the fill material is resistant to corrosion and degradation due to environmental conditions like high humidity or saltwater exposure.

Considering factors like these will help you ensure your cooling tower fill works at optimal efficiency and avoid penalties for compliance issues in your cooling tower.

Contact Cooling Towers LLC Experts

If you’re unsure whether your current fill is right for your system or if it’s time for a replacement, our team is here to help. We specialize in cooling tower inspections, maintenance, and repairs, and we can recommend the best fill material to meet your needs. Contact us today to schedule a consultation or inspection.