Film Fills
Film fills are high-performance cooling tower fill media that allow water to form thin flowing sheets, maximizing water surface area for efficient heat transfer. Recognized as the most energy-efficient and reliable cooling tower fills, they are ideal for industrial, commercial, and HVAC cooling towers. In both counterflow and crossflow towers, film fills let smaller towers achieve the same cooling capacity as larger splash-fill systems, offering a cost-effective and space-saving solution. Manufactured to CTI standards for long-lasting durability and optimal thermal efficiency, these premium film fill media are trusted by experts like Thermal Care Engineers.
Film fills are designed for direct replacement, performance enhancement, and water compatibility. Each type is optimized for different heat loads, flow rates, and water quality, ensuring efficient and reliable cooling performance from Thermal Care Engineers.
We provide a range of premium fill media at Thermal Care Engineers.
- Thermal Care Model ‘TC-12’
- Thermal Care Model ‘TC-19’
- Thermal Care Model ‘TC-LC19’
Advantages – Thermal Care Fill Media
- Enhanced Heat Transfer: Generates a larger surface area for more efficient cooling.
- Low Airflow Resistance: Minimizes pressure drop, improving energy efficiency.
- Compact Design: Reduced fill height with higher cooling capacity, resulting in lower power consumption.
- Durability: Long-lasting performance when used with good-quality water.
- High Strength & Safety: Self-supporting, high-strength, and self-extinguishing characteristics.
- Reinforced Edges: Folded sheet edges provide maximum structural integrity.
- Cost-Effective Construction: Fewer support beams required, reducing construction costs and pressure drop.
Key Features of Film Fills
- High Heat Transfer: Maximizes water surface area for efficient cooling.
- Low Airflow Resistance: Reduces pressure drop and energy use.
- Compact Design: Smaller fill height with high cooling capacity.
- Durable Materials: PVC, PP, or ABS for long-lasting performance.
- Strong Structure: Folded edges ensure high load-bearing capacity.
- Flexible Designs: Cross-fluted and vertical flutes for thermal efficiency and clog resistance.
Industrial Applications of Thermal Care Film Fill
- Power Plants: Cooling towers for thermal and hydroelectric plants.
- HVAC Systems: Air-conditioning and climate control for commercial and industrial buildings.
- Process Industries: Chemical, petrochemical, and pharmaceutical cooling towers.
- Manufacturing Units: Steel, cement, and food processing plants.
- Water Treatment Plants: Efficient cooling for large-scale water systems.
- Other Industrial Applications: Any facility requiring high-efficiency heat rejection.
Why Choose Thermal Care Engineers Film Fill?
- Film Fill Manufacturer in Mumbai: In-house production ensures durable, uniform, and high-performance film fills.
- Cooling Tower Film Fill Supplier: We provide TC-12, TC-19, and TC-LC19 tailored for varied water qualities and industrial applications.
- Customized Film Fill for Cooling Towers: Cross-fluted and vertical fluted designs for efficient cooling and clog resistance.
- Industrial Film Fill Manufacturer: PVC, PP, and ABS construction with UV and chemical resistance for long-lasting performance.
- Film Fill Installation Services in Mumbai: Modules can be supplied factory-assembled or site-assembled, ensuring easy installation.
- High-Performance & Anti-Clog Film Fill for Industrial Cooling Towers: Optimized design reduces airflow resistance, energy consumption, and maintenance costs.
The TC-12 fill is ideal for HVAC applications and other industries where the makeup water contains low TSS. Cooling towers using TC-12 should have minimal contamination from oil, grease, or process dust.
This cross-fluted film fill works by forming a thin water film on the media surface. The polymer’s surface tension retains the film long enough for efficient heat transfer with ambient air.
With a 12 mm flute height and Thermal Care’s optimized microstructure, TC-12 provides an effective surface area of 250 m²/m³, ensuring maximum thermal performance (KaV/L)
Technical Specifications
| Characteristics | TC-12 |
|---|---|
| Primary Cooling Towers Application | Counterflow |
| Flute height | 12 mm |
| MOC | Rigid PVC (Virgin and reprocessed) |
| Longitudinal pitch | 37.5 mm |
| UV Stabilization | White - Titanium Dioxide Black - Carbon Black |
| Spiral angle | 28o |
| Std. Sheet size L x W |
600mm x 300mm |
| Recommended Max Fill Sheet size L x W | 1200 mm x 600 mm |
| Surface area per unit volume | 258 m2/m3 |
| Standard Weight | 26.5 Kgs/m3 |
| Maximum continuous Operating temp. | 55 oC |
| Minimum Fill Sheet Finished Thickness | 0.175 mm |
| Standard Followed for Material properties | CTI STD-136 |
Features and Advantages – Thermal Care TC-12
- In-House Calendering Units: Ensures proper fusion of PVC and additives, delivering superior mechanical strength, physical durability, and uniform sheet thickness. Unlike most fill manufacturers who outsource, Thermal Care maintains full quality control in-house.
- Enhanced Glue Point Locator: Precisely positioned along the flutes for stronger modules and a well-defined honeycomb structure, enhancing cooling tower efficiency.
- Double Folded Edges: Both sides of the sheet feature folded edges for maximum load-bearing strength. A 0.175 mm sheet (0.35 mm at edges) matches the application strength of a 0.25 mm standard flute fill.
- Material and Color Options: Available in Translucent White / White (UV+IR stabilized), Blue (sunlight resistant), and Black (UV stabilized), providing durability in varied environmental conditions.
- Flexible Supply Options: Supplied as factory-assembled modules or on-site assembled modules, offering ease of installation.
- High-Temperature Applications: Manufactured using PP and ABS, suitable for high-temperature cooling tower operations.
The TC-19 fill is a high-efficiency, workhorse film fill designed for cooling towers in power plants and process industries. It is ideal for applications where the makeup water may contain TSS up to 100 mg/L and microbiological control may be limited, assuming standard water treatment procedures are in place for oil, grease, and heavy salt removal.
TC-19 is a cross-fluted film fill that spreads water into a thin film on the media surface. The polymer surface tension retains the film long enough for efficient heat transfer with ambient air. With a 19 mm flute height and Thermal Care’s optimized microstructure, TC-19 provides an effective surface area of 158 m²/m³, ensuring high thermal performance (KaV/L) and reliable cooling efficiency.
Technical Specifications
| Characteristics | TC-19 |
|---|---|
| Primary Cooling Towers Application | Counterflow |
| Flute height | 19 mm |
| MOC | Virgin rigid PVC |
| Longitudinal pitch | 50 mm |
| UV Stabilization | White - Titanium Dioxide Black - Carbon Black |
| Spiral angle | 28o |
| Std. Sheet size L x W |
1200mm x 600mm |
| Recommended Max Fill Sheet size L x W | 1800 mm x 600 mm |
| Surface area per unit volume | 158 m2/m3 |
| Standard Weight | 27 Kgs/m3 |
| Maximum continuous Operating temp. | 55 0C |
| Standard Fill Sheet Finished Thickness (Available in 0.23mm thickness Other thickness on request) |
0.25 mm |
| Standard Followed for Material properties | CTI STD-136 |
Features and Advantages – Thermal Care TC-19
- In-House T-Die/Calendering Units: Virgin PVC resin is processed internally, ensuring proper fusion with additives for superior mechanical strength, physical durability, and uniform sheet thickness. Unlike many manufacturers who outsource, Thermal Care maintains full quality control.
- Double Folded Edges: Both sides of the sheet are folded for maximum load-bearing strength. A 0.25 mm sheet (0.5 mm at edges) provides the equivalent application strength of a 0.38 mm standard flute fill.
- Lightweight Design: Minimum weight per unit volume ensures easier handling and allows for cost-effective support structures.
- Enhanced Gluing Points: Defined top and bottom glue points along the flutes reduce glue consumption per cubic meter by up to 30%, while creating a better visible honeycomb structure.
- Material and Color Options: Available in Black (UV stabilized) and Translucent White / White (UV+IR stabilized) for durability under varied environmental conditions.
- Flexible Supply Options: Can be supplied as factory-assembled modules or site-assembled modules for convenient installation.
The TC-LC19 fill is a high-performance cross-corrugated PVC fill media, designed for maximum thermal efficiency and mechanical strength in cooling towers.
For applications where makeup water quality is lower, with TSS up to 200 mg/L, TC-LC19 offers a vertical fluted design. This configuration delivers excellent thermal performance while being less prone to clogging compared to standard cross-corrugated film fills.
Technical Specifications
| Characteristics | TC-LC19 |
|---|---|
| Primary Cooling Towers Application | Counterflow |
| Flute height | 19 mm |
| MOC | Virgin rigid PVC |
| Longitudinal pitch | 50 mm |
| UV Stabilization | White - Titanium Dioxide Black - Carbon Black |
| Spiral angle | 00 |
| Std. Sheet size L x W |
1200 mm x 600mm |
| Recommended (for ease of module making) Max Fill Sheet size L x W |
1800 mm x 600 mm |
| Surface area per unit volume | 146 m2/m3 |
| Standard Weight | 35 Kgs/m3 |
| Maximum continuous Operating temp. | 55 0C |
| Minimum Fill Sheet Finished Thickness | 0.3 mm |
| Standard Followed for Material properties | CTI STD-136 |
Features and Advantages – Thermal Care TC-LC19
- Reduced Clogging and Bio Growth: The absence of intersection points in alternate sheets prevents accumulation of suspended solids and limits biofilm development.
- Vertical Flute Design: Large openings between sheets allow higher water velocities, enabling debris and particles to pass through easily.
- Lower Weight Gain: Over time, vertical fluted fills experience less weight gain from deposits compared to cross-corrugated film fills, ensuring long-term performance.
- Mixed Fill Configuration: Can be combined with a small cross-corrugated layer at the top, providing effective water distribution while keeping the bottom portion clog-free.
- Higher Cycles of Concentration: Optimized design allows higher cycles of concentration for the cooling tower water, improving water efficiency.