The Evolution of Chiller Technology: A Field Guide to Six Major Types

Using chilled water to remove heat has been the industry standard for large facilities for good reason: it's reliable, and it's fairly straightforward to control. Chillers have served as the cooling backbone for these facilities for over a century. During our 50 years in business, MSC has serviced just about every type of chiller system, and we've seen the technology evolve significantly.

HVAC chillers date back to May 1922, when Willis Carrier unveiled the first centrifugal refrigeration machine at the Whitman & Sons Candy factory in Philadelphia. MSC's own history with chiller systems goes back to the mid-1970s, when we began working with reciprocating machines for vapor recovery and process cooling, along with centrifugal chillers in central utility plants. At the time, heat rejection came down to two basic methods: water-cooled systems using a cooling tower, or air-cooled systems using a condenser coil.

Where the Technology Stands Today

Over the years, MSC has watched screw and centrifugal compressors become the go-to choices for mission-critical applications where reliability is essential. Scroll compressors, once primarily a residential technology, have made major strides in commercial applications, as well. Variable frequency drives have improved reliability across the board and given systems much better control at both low and high demand.

Reciprocating chillers are still in use across many industries, though they haven't seen the same growth in popularity as other systems. They remain relevant in smaller or specialized applications where precise temperature control matters enough to offset the added maintenance and noise compared to screw or centrifugal systems.

The industry's clearest trend, though, is toward heat recovery. Heat pump chillers now recover heat for reheat hot water and other purposes, and geothermal systems use a closed ground loop as a natural heat exchanger. Absorption chillers tell a similar story: they lost favor over the years due to their larger footprint and the added maintenance involved in monitoring and adjusting the lithium bromide solution that drives the cooling cycle. Most of the gas-fired absorption systems MSC maintained over 30 years ago were eventually replaced with centrifugal chillers. Now, they’re making a real comeback, this time powered by rejected heat rather than gas, a shift that aligns well with decarbonization mandates and eliminates the need for refrigerants altogether.

It's also worth mentioning the advancements happening on the controls side. MSC has seen just as much innovation in hardware, software, and instrumentation as we have in the mechanical equipment itself. Automated monitoring systems now track numerous parameters, flag where corrections are needed, and help fine-tune performance and sequencing.

Here’s how the six major chiller types and configurations compare:

Scroll Chillers

Features: Compact and lightweight design with fewer moving parts, which supports high reliability. Quiet operation makes them a good fit for noise-sensitive environments.

Advantages: High efficiency, particularly at part-load conditions. Easy to install and maintain.

Disadvantages: Limited capacity range, typically topping out around 30-60 tons. Not well suited to large-scale industrial use.

Screw Chillers

Features: Twin-screw compressors capable of handling large cooling loads (200 tons and up), with strong efficiency across varying load conditions.

Advantages: High efficiency and reliability, with lower maintenance costs than reciprocating chillers.

Disadvantages: Higher upfront cost and a larger physical footprint.

Reciprocating Chillers

Features: Piston-driven design, versatile across a wide range of sizes and capacities.

Advantages: Precise temperature control and efficient operation across diverse conditions.

Disadvantages: More moving parts mean higher maintenance needs, and operation tends to be noisier than screw or centrifugal chillers.

Centrifugal Chillers

Features: Uses centrifugal force to compress refrigerant, typically built for large capacities (300 tons and above).

Advantages: Highly efficient for large cooling demands, and can be paired with variable frequency drives for even better efficiency.

Disadvantages: Higher initial investment and a need for skilled maintenance.

Heat Pump Chillers

Features: Capable of both heating and cooling, available in air-source and water-source configurations.

Advantages: Energy-efficient and versatile for year-round climate control.

Disadvantages: Performance can dip in extreme outdoor temperatures, and upfront installation costs run higher.

Absorption Chillers

Features: Thermal-driven process, often powered by rejected heat, steam or hot water, rather than mechanical compression

Advantages: A strong fit for combined heat and power (CHP) systems and waste heat recovery. No moving parts in the cooling process means quieter operation.

Disadvantages: Lower efficiency than mechanical chillers, especially at smaller capacities, along with higher initial costs and a larger footprint.

What This Means for Your Facility

Centrifugal and screw chillers continue to dominate large commercial and industrial settings thanks to their efficiency at scale. Scroll chillers are a strong fit for smaller applications where compact design and quiet operation matter, and heat pump chillers are increasingly valued for their versatility and sustainability. Absorption chillers, while less common, are worth a closer look in settings where their advantages, especially waste heat recovery, can be put to real use.

So, what is the right chiller for your facility? It comes down to your load, application, space, budget, and goals. That's where MSC comes in. We've been servicing these systems since the 1970s and have watched the technology evolve firsthand. Please contact us at (973) 884-5000 to discuss the best fit for your facility and how we can help keep it properly serviced and maintained.