The Environmental Advantage of Cooling Towers vs Once-Through Cooling Systems

Industrial Cooling Tower

Did you know that before industrial cooling towers existed, there was a more archaic system called once-through cooling (OTC)? The old system, while functional, wreaked much more havoc on the environment, paving the way for innovative solutions to take their place.
Unfortunately, even though new factories and plants aren’t built with OTC systems, there is still a large percentage of older installations (particularly along the east coast) that haven’t been upgraded. To understand how important industrial cooling towers are, it’s necessary to understand why they were so needed in the first place. In this post, we’ll explore some of the reasons why cooling towers are a far better solution than OTC systems.

How it Works

Industrial cooling towers and OTC mechanisms both serve the same purpose — they’re both water cooling systems that are utilized in factories and plants. The functionality of a water cooling system is relatively simple; machines get hot, and water is used to cool them down.
In a once-through system, the factory withdraws a large amount of water from a local water source, runs it through their system, and then dumps it all out back into where it came from. Meanwhile, a system that uses cooling towers recycles the water, cooling it down so it can be reused for its original purposes. Once-through is a “one and done” system, while recirculating systems operate in a way that’s more economical and efficient.

Why OTC Is Harmful to the Environment

Tainted Water Kills the Wildlife

In an OTC system, a large amount of water is sucked into the factory or plant, and circulated through its entire system, cooling the various machines and technology that run too hot. Once the water has done its job, it’s dumped back into the source.
The water that returns isn’t the same water that went in — technically it is, but the returning water is usually scathing hot, and tainted with residue from the metals that make up the factory. The temperature change and chemicals kill a fair share of local wildlife.
The Cooling Tower Advantage: With cooling towers, water isn’t returned to the source at all. Instead, it’s withdrawn into the factory and recirculated. Evaporating techniques remove the heat out of it, so it can go multiple rounds. Tainted water can’t kill fish when it never gets back into the source to begin with.

Excessive Water Consumption

One major problem with OTC systems is that they withdraw massive amounts of water for every single cooling cycle. Even though the water is eventually returned, it’s tainted, and some of it is lost every time. In an area with a limited water supply, an OTC plant can suck the area dry over time.
This also spells disaster for local water life; depleting habitats predictably wreak havoc on animal populations, and even land animals can start to suffer when their supply gets too low.

The Cooling Tower Advantage: Industrial Cooling Towers solve this problem because they’re much more generous in the way they withdraw water. Essentially, once it’s pulled in enough water to cool its systems, the water is recirculated and cooled by the towers. The heat is evaporated out of the supply, so a small amount of water is lost, but most of it remains, ready for the next cycle.
The next time the system withdraws water, it will only pull in the amount that was lost, which is negligible compared to an OTC plant.
It might seem like this would lead to long-term water loss; the factory never returns water and keeps drawing more, so it would deplete in the long-term, right? While the logic is sound, in reality, most water sources are able to replenish at an equal rate through natural means, such as rivers or rainfall. OTC systems pull out quantities that are too big too often, preventing the source from being able to keep the pace when it replenishes itself.

Industrial Cooling Towers – An Elegant Solution

Now more than ever, it’s important for us to be good stewards over the environment that we’re a part of, and this couldn’t be more true than with factory and plant owners, who have the potential to inflict enormous damage on surrounding ecosystems if they’re not careful.
Fortunately, industrial cooling towers have solved many of the problems that OTC plants cause. We’re moving in a positive direction, and at Industrial Cooling Solutions, we’re happy to supply companies with high quality industrial cooling towers that are not only more efficient than the old system, but more environmentally conscious as well. Do you have a need for cooling solutions? Contact us today for a free quote!

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Comments (0) March 28, 2018 /

Why FRP is Superior to Wood, Aluminum, Steel, and Concrete

Industrial Cooling Tower

While the type of materials that make up industrial cooling towers probably isn’t something that you find yourself pondering in your spare time, it’s nonetheless something that you’ll have to be aware of when it comes to getting a new cooling tower. Whether you’re installing a new system entirely or replacing some of your older industrial cooling towers, investing in the right material will go a long way.
At Industrial Cooling Solutions, it’s no secret that we believe FRP (fiberglass reinforced polymer) is the best choice for your cooling towers. Wood, steel, concrete, and aluminum are all materials that cooling towers can be made with, but we believe that FRP is far and away the best choice, for several reasons.

Corrosion Resistance

Corrosion, in the context of cooling towers, is the gradual decay or deterioration of its material due to the surrounding environment. Since industrial cooling towers spend 100 percent of their time exposed to the elements, it’s important to consider a material that will hold up well.

Wood: Wood can warp, rot, or decay from exposure to water and other elements. It is also susceptible to insect damage (such as termites). Due to these weaknesses, it’s customary to apply preservative coatings over the tower, which, unfortunately, aren’t very environmentally friendly.

Steel and Aluminum: Both of these are metals, making them susceptible to oxidation and corrosion via rust. These require painting, galvanizing, or anodizing.

Concrete: Concrete doesn’t naturally decay very easily, but it is porous, making it an easy target for dirt and bioforms to accumulate, which requires copious amounts of cleaning and maintenance in the future.

FRP: FRP is completely resistant to water and moisture, and has strong resistance to a wide variety of chemicals. Being a synthetic material, it holds its own against the elements much more efficiently than the other materials do.

Strength and Flexibility

Strength and flexibility are important when it comes to cooling towers, especially when it regards their longevity. They need to be able to take an appropriate amount of stress, and weather attacks from mother nature, such as hurricanes or earthquakes.

Wood: Wood is weaker than FRP in just about every measurable aspect. FRP is stronger, and has higher flexural strength. Overall, wood doesn’t have a strong argument here.

Steel: Steel is, unsurprisingly, extremely heavy, weighing 75 percent more than FRP. It carries so much weight that heavy listing equipment is often needed just to be able to move it around. Furthermore, steel is flexible under heavy pressure, and it doesn’t like to bend back to its original shape once it has been transformed.

Aluminum: Aluminum is appealing due to its famously light weight. But guess what? FRP is still lighter, clocking in at about 75 percent of aluminum’s weight. While aluminum is technically stronger than FRP in sheer numbers, FRP is overall stronger when you consider it on a pound-for-pound basis.

Concrete: The yield strength of concrete is absurdly high, but concrete also suffers from having no flexibility, making it rather brittle in the face of damage. Earthquakes are a dangerous threat for concrete towers; even the smallest one can cause a concrete tower to break into pieces.

FRP: FRP is highly elastic but engineered in such a way to where it doesn’t permanently deform. It’s also extremely lightweight, making it the easiest material to handle and install. When it comes to weight to strength ratio, it’s the strongest of them all.

Electrical Conductivity

Although most cooling towers are engineered to withstand the effects of errant electricity, it’s nonetheless important to keep them protected from it to the best of your ability. Cooling towers are closely tied with your water flow, and given the conductivity of water, it’s generally good advice to just protect your towers from lightning as much as possible.

Wood, Steel, and Aluminum: All three of these materials are conductive, particularly the latter two, though those have potential for grounding. Wood is most conductive when it’s wet, but in the case of a lightning strike, this is highly likely due to the presence of rain.

Concrete: Concrete isn’t conductive, putting it on equal ground with FRP in this category, but it is still more susceptible to environmental damages as a whole.

FRP: FRP is completely non-conductive, and has high dielectric capability. There’s not much more to say here — it doesn’t conduct electricity at all, so that’s a problem you’ll never have to worry yourself about.


An important factor for any business owner is cost — of course superior options always exist, but are they worth the extra price? Fortunately, an FRP industrial cooling tower is quite affordable.

Wood: Wood has a lower initial cost than FRP, but almost always requires long-term maintenance and a shorter product life. Wood gradually corrodes and is susceptible to insect damage. While the upfront cost is cheaper, you save more in the long-run with FRP by avoiding the repeat costs that wood incurs.

Concrete: Concrete is much costlier in the long-term, especially since they’re particularly vulnerable to cracking. Installation costs more with concrete industrial towers, due to the process of engineering, casting, and drying that’s tailor made for your business. Concrete takes a long time to set, which also lengthens the installation process significantly.

Steel: Steel has a lower cost for the initial materials, but the installation is significantly more expensive, and like the other materials, is subject to much more long-term maintenance costs than FRP.

Aluminum: Aluminum is the one material that slightly edges out FRP in the cost department. FRP tooling costs and price per lineal foot are marginally higher.

FRP: FRP edges out all of the other materials save for aluminum in cost. And, despite aluminum’s cheaper price tag, it could be argued that FRP is still a better deal due to the various other advantages that it has.


Overall, when you look at the big picture, FRP edges out all of the other materials when it comes to high-quality industrial cooling towers. It lasts longer, it’s stronger and yet more elastic, it’s cheaper, safer, and it’s easier to maintain and install. It’s hard to argue that FRP isn’t the best solution by far, and that’s why, at Industrial Cooling Solutions, we offer FRP in spades. Whether you’re repairing an FRP tower and need parts, installing a new tower entirely, or replacing an older obsolete one, you can’t really go wrong with FRP industrial cooling towers. Having a functioning cooling system in your plant and factory is supremely important, and we want to make sure everybody has a functional and reliable solution. We will happily provide you with industrial cooling tower solutions, or provide you with the parts you need to make repairs on our own. Whatever your need is, we can cover it, so if you’re in the need for Industrial Cooling Solutions, contact us today for a free quote!

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Comments (0) March 19, 2018 /

Concrete Versus FRP Cooling Towers Pt. 2

Cooling Tower Services Industrial Cooling Tower


Is an FRP Cooling Tower the Right Choice for Your Project?

Hello, dear reader, and welcome to part two of our blog series highlighting the advantages that FRP materials have over concrete in industrial cooling tower design. While we aren’t suggesting that certain applications won’t call for a concrete tower design, overall we are confident that FRP materials are a better choice in the majority of cases. In our last post, we listed a couple of advantages FRP has during the construction and design phase and, in today’s post, we are going to highlight some of the maintenance benefits associated with FRP cooling towers. We hope that by the end of this blog you feel more confident in your decision between these two materials.

Maintenance is a Necessary Part of Industrial Cooling Towers

All machines, no matter how well they are designed and manufactured, require maintenance. Industrial cooling towers are no exception to this rule and, often, maintenance costs over the life of the tower can become quite an expense. Below, we have listed a few ways that FRP cooling towers are easier to maintain than concrete cooling towers.

  • Cleaning: If you have spent time around an industrial cooling tower, you are well aware that they require routine, thorough cleaning. Scale buildup and biological growth can quickly inhibit the efficacy of a cooling tower and must be handled accordingly. FRP cooling towers allow for scale build-up and algae to be washed or brushed away with ease. Concrete cooling towers, on the other hand, are porous and tend to hold onto undesirable particles and growth that must be thoroughly scrubbed away. Not only do concrete cooling towers require more frequent cleanings, the amount of labor required to complete those cleanings is much more when compared to an FRP tower.Further, the closer spacing of the structure in the FRP cooling tower allows for easier cleaning without excessive scaffolding. Concrete towers have large spans in structure, thus requiring substantial pre-cleaning safety planning and large amounts of costly scaffolding to allow cleaning teams to safely access and clean the structure.
  • General Maintenance: Every industrial cooling tower requires maintenance at some point. FRP cooling towers are one of the easiest designs to maintain. If the tower structure becomes damaged in any way, the identified components can simply be removed and replaced and the tower is good as new. If a concrete cooling tower becomes damaged, however, things aren’t as easy. Concrete tends to crack and corrode over time and repairs can be costly, expensive, and time consuming. Especially in brackish or seawater conditions which can be very aggressive to concrete structures. Where FRP cooling towers can be repaired in a matter of hours, concrete cooling towers require substantial time for preparation, chipping, patching and time for the concrete to cure, a process which can take days.

We hope that this short blog series has done an adequate job in explaining the reasons we believe that FRP cooling towers are superior to concrete cooling towers for the majority of applications. FRP towers are much faster and easier to assemble, require less maintenance, and perform better than concrete cooling towers over their lifespan. If you would like to learn more about our FRP cooling tower options, please visit our website today. At Industrial Cooling Solutions Inc. we are experts in the design, construction, and maintenance of FRP industrial cooling towers and we would love to leverage our experience to help you with your next cooling tower project.

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Comments (0) March 29, 2017 /

Concrete Versus FRP Cooling Towers

Industrial Cooling Tower


Which Material is Right for Your Cooling Tower?

At Industrial Cooling Solutions Inc., we want to make industrial cooling tower design as easy as possible. We realize that, for the most part, our clients are interested in two things: efficiency and installation cost. To help provide some more information on these particular concerns, we are going to spend today’s post explaining the difference between two of the most common cooling tower construction materials, concrete and FRP and why we feel that FRP out performs concrete in almost every category. Continue reading below to learn more.

FRP Materials Offer Certain Benefits Over Concrete

Designing, installing, and outfitting an industrial cooling tower for a project take a lot of time, energy, and effort. Because of this, it is important that the best material is chosen for the job. Once installed, cooling towers become an integral part of the facility they are attached to and ideally the tower or towers will last for a long time. Below, we have listed a few of the differences one should be aware of when making the decision between an FRP or concrete cooling tower.

    • Quality:  When constructing a cooling tower, quality is of the utmost importance. FRP structural components are produced by on off-site factory that inspects and certifies each component before it leaves the factory. An additional inspection is performed before the components are put in place to double check that the materials are up to our standards. Concrete, on the other hand, is poured in place on site and cannot be accurately inspected until the concrete has cured. This makes certifying the structural integrity of concrete cooling towers much more challenging than FRP towers. Additionally, because all FRP structural components are pre-drilled at the factory, the overall dimensional accuracy of the tower can be better gauged than concrete towers which must be constantly measured to ensure that their dimensions are accurate and that they are level.
  • Construction: In most cases, construction of an industrial cooling tower must be completed in a timely manner. Designing and building an FRP cooling tower can be done in a quicker, simpler manner than a concrete cooling tower because once the overall design is completed, the structure can immediately be put into production. Concrete cooling towers, however, require a great deal of engineering and communication to finalize the design and before the cooling tower can even be constructed, large concrete foundations must be set in place to handle the weight of the tower. The construction process for concrete cooling towers is further slowed down by the fact that each segment of the tower must be allowed to dry before another segment can be placed. Because FRP cooling tower segments are lightweight and pre-molded, the basic framework of the tower can be completed in as little as a few days compared to the few week required for concrete towers.

Join us again next time as we continue to go over why we feel that FRP materials are a better choice for your cooling tower design than concrete. If you’re already convinced that FRP is the perfect material for your project, please contact us today for a consultation. We have the knowledge, tools, and experience necessary to handle any industrial cooling tower project that you may have.

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Comments (0) March 29, 2017 /

Industrial Cooling Tower Materials

Industrial Cooling Tower

Industrial Cooling Towers are Made From Many Materials

Here at Industrial Cooling Solutions Inc., we have a wealth of experience in building industrial cooling towers. These towers are vital to a wide range of businesses including, but not limited to, power generation, chemical plants, metal processing plants, and fertilizer production. With such a wide range of businesses in need of industrial cooling solutions, options had to be made available to fit each application’s needs. A cooling tower that may be perfect for a geothermal power plant might not work as well for a plant the specializes in producing industrial chemicals. In today’s post, we are going to go over the different types of materials used in the construction of industrial cooling tower and the advantages and disadvantages that they offer.

Industry and Environment Greatly Affect Industrial Cooling Tower Design

When determining what materials to use in constructing our industrial cooling towers, we here at Industrial Cooling Solutions Inc. consider a wide range of variables. To select the right materials, our team of engineers consider factors such as usage of the tower, the climate of the area the tower will be located, type of exposure to corrosive agents, imposed loads, cost, and the availability of materials in relation to the construction site. Once we have done this research, we determine what type of tower will best suit the needs and budget of our clients. Most commonly, we build towers out of three types of material.

  • Wood: Most early cooling towers were built out of wood. At the time, wood was cost-effective, resilient, and, most importantly, easier to work with. In the modern world of industrial cooling towers, wood towers are less common because they are susceptible to environmental factors and are less durable than other types of towers. Despite these drawbacks, wood towers can be desirable for certain projects because they can be constructed quickly and at a lower cost than other cooling tower types.
  • Fiberglass Reinforced Polymer: In recent years, fiberglass reinforced polymer, or FRP, has become an increasingly popular choice for industrial cooling tower construction. FRP is praised for its reliability and durability and is also highly cost effective. FRP towers are chemically resistant, lightweight, inorganic, and able to resist rot and decay. Additionally, FRP is sometimes desired in place of wood because it is naturally fire retardant, stronger than wood, and more flexible than wood. This flexibility is especially important in areas that experience heavy storms or an excessive amount of ice build up.
  • Concrete: Although concrete towers have many benefits, depending on the country, location of the construction site, and the availability of materials to both mix and reinforce the concrete, concrete may or may not be a cost-effective material choice. However, if concrete is deemed to be the best material to use on a project, it comes with a plethora of benefits. Concrete is long lasting, fireproof, requires very low maintenance, and is an ideal material to use in areas where the industrial cooling tower will be exposed to harsh elements. Though the initial cost may be higher than other materials, concrete is a great material to use if longevity and durability are a main focus in the tower’s design.

We hope that this blog has helped to shed a little more light on the materials used in industrial cooling tower construction projects, why certain materials are used over others, and the advantages that these materials offer to our clients. Here at Industrial Cooling Solutions Inc., we handle every project with a level of care and dedication that sets us apart from the competition. We have built a wide variety of industrial cooling towers in a wide range of conditions and environments, allowing us to gain experience that we can pass onto our clients. We complete our projects in a timely, safe, and efficient manner, helping your industry get back to business with as little interruption or downtime as possible.
When you are ready to plan your next industrial cooling tower construction project, contact the experts at Industrial Cooling Solutions Inc. We have the knowledge, experience, and resources to deliver high-quality industrial cooling towers to a wide range of industries. Don’t settle for second best, contact us today and get your project rolling.

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Comments (0) January 31, 2017 /

Common Industrial Cooling Tower Issues

Industrial Cooling Tower Industrial Cooling Tower

Industrial Cooling Towers, Like All Things, Experience Issues

As anyone will tell you who has purchased any type of machinery, issues crop up. While machines are designed to be as durable and efficient as possible, they all inevitably need maintenance. Nothing performs perfectly forever and this is especially true for industrial grade machinery. Industrial machines have to deal with a workload that is near constant and, as a result, need much more maintenance than a lawnmower or car engine. Although industrial cooling towers are designed to be as efficient and maintenance-free as possible, they too occasionally need a little tender love and care. In today’s post, we here at Industrial Cooling Solutions Inc. are going to go over some common issues that can industrial cooling towers develop and how to properly maintain them.

Water is Both the Best and Worst Thing for Industrial Cooling Towers

Although some industrial cooling tower designs do not make use of water, the vast majority do. Water is, so far, the best options for eliminating heat from industrial processes because it is efficient and cost effective. However, anyone who has dealt with a machine that must deal with water knows that water can cause some pretty nasty issues. This is compounded with industrial cooling towers because often times the water picks up contaminants from the heat that it is trying to mitigate. Below, we have listed the most common issues that arise in industrial cooling towers due to water.

  • Scale Buildup: The buildup of scale is one of the most common issues in the world of industrial cooling. Scale if most often formed by the build up of inorganic mineral compounds present in the water such as calcium phosphate, iron oxide, and magnesium silicate. As scale buildup coats the inside of an industrial cooling tower the heat transfer efficiency is reduced. If the scale buildup is left unattended, it can lead to higher energy costs to run the cooling tower and may even require the entire cooling system to be shut down and serviced. The best way to prevent scale buildup is to routinely clean towers and reduce the amount of mineral buildup.
  • Corrosion: While it is true that over time water will corrode just about any substance known to man, water is not the main culprit when it comes to corrosion in industrial cooling towers. While it is true that water is the vehicle that provides the corrosive elements to travel, the elements themselves are more harmful than the water could every be. Many industrial cooling towers are exposed to harsh industrial chemicals during their lifespans. Corrosion can become a major issue because it can decrease cooling efficiency, increase energy costs, and in extreme cases cause damage or destruction to equipment within the tower. Again, the best way to mitigate corrosion is to routinely clean towers. Additionally, choosing tower materials that are naturally resistant to corrosion, such as FRP, is a great way to eliminate the problem of corrosion.
  • Fouling: Fouling simply refers to the process by which the water in an industrial cooling tower becomes soiled. Because so many industrial cooling towers scrub dirt, dust, and chemical components out of the air that they are cooling, the water can quickly become contaminated. If left untreated, this soiled water can clog up the water nozzles in the tower, reducing efficiency and increasing energy consumption. To help reduce the amount of fouling that occurs, it is important to have a well-maintained filtration system as well as a chemical treatment to break down the contaminants in the water.
  • Microorganisms: While the previous issues were mostly the fault of chemicals found in the water of industrial cooling towers, microorganisms can be blamed entirely on the water itself. Everyone knows that if air and water mix for a long enough period of time in a closed environment, things are going to begin to grow. Algae, bacteria, and fungi can all form in industrial cooling towers and can have some serious effects on the health of those that are around the cooling tower on a daily basis. Additionally, the buildup of algae and fungi can reduce the efficiency of heat transfer, compromise the integrity of the tower, and increase energy loss. To prevent the development of microorganisms in an industrial cooling tower, it is important to clean the tower routinely with an anti-microbial cleaner.

When you are in need of industrial cooling tower maintenance, contact us today at Industrial Cooling Solution Inc. We will ensure that your industrial cooling tower(s) is running as efficiently as possible and perform any maintenance to improve performance. Don’t let your tower degrade, contact us today.

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Comments (0) January 31, 2017 /

Cooling Towers Are Pivotal To Middle Eastern Development

Industrial Cooling Tower

Industrial Cooling Towers Are Essential in the Middle East

If you have been following along with our blog, you probably know just how much we enjoy talking about industrial cooling towers. These towers are essential for a wide range of industries and make it possible for many of the products that we know and love to be produced in an effective and environmentally safe way. Without industrial cooling towers, excessive heat build up would prevent many factories and plants from operating and this is especially true for industries that are located in extremely warm climates. In today’s post, we are going to focus on the benefits that industrial cooling towers have had on the growing industrial sector in the Middle East.

The Middle East Has a Wide Range of Industries

When the average person thinks of the economy of the Middle East, their thoughts most likely go to one essential exported good: oil. While it cannot be denied that oil is one of the most important economics for a multitude of countries in the Middle East, the last few decades have seen a large growth in the industrial sector as well. Anyone who has been paying attention to trends in the energy sector knows that oil is on its way out. While this resource will not be completely phased out anytime soon, the growth of the renewable energy sector shows that the world, as a whole, is ready to shed the shackles of oil dependence. While this move to renewable energy will be a net positive for the planet, it is undoubtedly going to cause some ripples in the world’s major oil producing nations. As a result of this shift in the energy sector, many oil producing nations are looking for alternative ways to ensure that the economy of their country still thrives. This has resulted in an increased presence of industries in the Middle East and, as a result, an increased need for industrial cooling towers.

The Middle East is Hot. Cooling Towers Help With That

Like the vast majority of industrial cooling towers, the ones located in the Middle East use water as their preferred choice of heat transfer medium. The most common uses of industrial cooling applications in the Middle East are central air conditioning plants, process cooling, industrial refrigeration, chemical plants, and textile manufacturers. While all of these plants are present in other countries, they pose a particular issue when they are located in the Middle East. You see, while water is the most effective method for dissipating heat for industrial applications, that becomes an issue if your plant is located in the middle of a desert. Countries such as Saudi Arabia, Kuwait, Jordan, and the UAE all must make use of industrial cooling towers to effectively run their industrial plants, but that can be difficult when water is not a resource that is abundant in your country. To combat this issue, industrial cooling tower technology has had to find effective ways to cool a factory in an area where water is a precious commodity.

The Middle East is Changing the Industrial Cooling Tower Game

So, how does an entire sector of industry keep up with the demand for cooling towers that can effectively eliminate heat in areas where water is scarce? Simply put, they innovate. The Middle East’s need for effective industrial cooling towers has spurred a renewed sense of innovation in the industry. Industrial cooling tower manufacturers are not going to ignore an entire sector of the globe and, as a result, have come up with more efficient ways for their cooling towers to operate. Advancements in FRP towers, better fill material, and increased water efficiency have largely resulted from having to come up with an effective way to cool plants and factories in areas of the world that have a hot climate. Here at Industrial Cooling Solutions Inc., we are dedicated to helping the world, the whole world, come up with effective means to responsibly eliminate heat from industrial processes.
To learn more about our industrial cooling towers and the services that we offer, contact us today at Industrial Cooling Solutions Inc. We are a global leader in industrial cooling tower construction and design and have worked on projects all over the world. Visit our website today and see why we are the best choice to handle your industrial cooling needs.

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Comments (0) January 24, 2017 /

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