Views: 0 Author: jessi Publish Time: 2026-09-03 Origin: Site
Cooling tower fill is one of the most important components in a wet cooling tower. It increases the contact area between air and water, improves heat transfer, and helps the cooling tower achieve the required leaving-water temperature. When cooling tower fill becomes clogged, damaged, or degraded, replacing it with the correct fill media can significantly improve system performance.
The U.S. market has a wide range of cooling tower fill manufacturers, OEMs, aftermarket suppliers, and component specialists. Products include PVC film fill, crossflow fill, counterflow fill, splash fill, low-fouling fill, and custom replacement fill.
Cooling tower fill, also called cooling tower packing or cooling tower fill media, is installed inside a wet cooling tower to increase the contact area between circulating water and air.
Hot water enters the cooling tower and flows over or through the fill material. At the same time, air moves through the fill section.
The fill creates a large water-air contact surface, allowing a portion of the water to evaporate. The evaporation process removes heat from the circulating water.
High-quality cooling tower fill can help:
Improve heat transfer efficiency
Increase water-air contact area
Reduce cooling tower approach temperature
Maintain stable thermal performance
Reduce energy consumption in some applications
Extend cooling tower operating life
Support cooling tower replacement and retrofit projects
Power Tower Cooling Technology is a Chinese manufacturer specializing in cooling tower components and replacement parts, including various types of cooling tower fill media.
The company provides cooling tower fills for different tower configurations and applications and serves international markets, including customers looking for replacement components for industrial cooling towers.
PVC cooling tower fill
PP cooling tower fill
UPVC cooling tower fill
Cross-flow fill
Counter-flow fill
S-wave fill
Round cooling tower fill
Splash fill
Wastewater cooling tower fill
The company's product range includes fill solutions associated with brands and tower configurations such as Liangchi, Lanxun, Spindle, Ebara, and Kingsun.
A broad range of fill geometries makes it easier to match replacement media with different cooling tower designs.
Cooling tower fill can be selected according to tower dimensions, water quality, operating temperature, airflow, and application requirements.
For Myanmar buyers, an international manufacturer can be an alternative when locally available replacement fill does not meet the required specifications.
SPX Cooling Technologies, through its Marley brand, is a major manufacturer of cooling towers and cooling tower replacement parts.
Marley offers a comprehensive range of cooling tower fill and drift eliminators, including counterflow film fill and crossflow film fill.
Major Marley fill products include:
DF254 Counterflow Fill
DF381 Counterflow Fill
FB20 Counterflow Fill
MC75 Counterflow Film Fill
MVC20 Counterflow Film Fill
MX Crossflow Film Fill
MBX Crossflow Film Fill
For example, MC75 uses thermoformed, UV-inhibited and chemically resistant PVC and is designed to create surface area and turbulence for efficient heat transfer.
Marley's MVC20 is a vertical-flute film fill designed with low-clog characteristics and reduced pressure drop, making it suitable for applications where fouling is a concern.
Baltimore Aircoil Company is another major U.S. cooling equipment manufacturer with an extensive replacement-fill portfolio.
BAC provides engineered cooling tower replacement fill kits for its equipment as well as selected competitor applications.
Its product portfolio includes:
BACross® Replacement Fill
VersaCross® Replacement Fill
QuickCross™ Replacement Fill
BAC Pak™ Replacement Fill
BACount® Replacement Fill
BAC replacement kits are designed around specific cooling tower models and can include:
Fill media
Supports
Hardware
Installation instructions
Integrated components
BAC states that VersaCross is designed to meet or exceed original performance specifications and fits most crossflow towers. The fill can also reduce installation and shipping requirements compared with conventional block fill.
Tower Components specializes in cooling tower and heat exchanger components.
The company supplies products for commercial HVAC, industrial process cooling, industrial refrigeration, and power generation applications. Its product range includes film fills, splash fills, and drift eliminators.
Its film fill products are available in different thicknesses and heights for different applications.
According to the company, its film fills can include:
High-efficiency designs
PVC and HPVC materials
Engineered microstructures
Improved water distribution
CTI Standard 136-compliant material
Solvent-welded construction
Tower Components serves applications such as:
Commercial HVAC
Industrial processing
Power generation
Industrial refrigeration
C.E. Shepherd is a U.S.-based manufacturer of cooling tower components with decades of industry experience.
Its product portfolio includes cellular fill, splash fill, drift eliminators, and cooling tower nozzles. Industry directories identify the company as a manufacturer and custom manufacturer of cooling tower components.
The company's cooling tower products are used for both crossflow and counterflow cooling tower applications.
Cellular film fill
Splash fill
Drift eliminators
Cooling tower nozzles
Its experience in cooling tower components makes it a potential supplier for industrial and replacement-fill projects.
Cooling Tower Products is an Arizona-based manufacturer and direct supplier specializing in aftermarket cooling tower parts.
The company has been serving the cooling tower industry since 1975 and provides replacement parts for multiple cooling tower brands.
Its product range includes:
Crossflow fill media
Counterflow fill media
Low-fouling fill
Cross-corrugated fill
PVC fill packs
Custom-size fill
The company states that its fill media can be supplied for brands including BAC, Marley, Evapco, Recold, Tower Tech, Vilter and others.
Cooling Tower Products offers standard and custom-size fill packs, which can be useful for older or obsolete cooling tower models.
C.T.P. Manufacturing is a U.S. cooling tower component supplier located in California.
Industry listings identify the company as a manufacturer and custom manufacturer of PVC fills for cooling tower applications. Its products are used in applications including HVAC, refrigeration, process cooling, power generation, petrochemical, steel, and pulp and paper industries.
Its focus on PVC cooling tower fill makes it relevant for:
Industrial cooling towers
HVAC systems
Process cooling
Refrigeration systems
Power generation facilities
For buyers searching for PVC cooling tower fill manufacturers in the USA, C.T.P. Manufacturing can be considered for projects requiring PVC fill and replacement components.
Cooling Tower Systems manufactures its own fill packs and provides PVC fill media for both counterflow and crossflow cooling towers.
The company can provide fill in different flute configurations according to thermal-load requirements.
Its fill can also be:
Cut to specified dimensions
Manufactured for specific tower configurations
Used for replacement projects
Supplied for CTS cooling towers
Adapted for other cooling tower designs
For a replacement project, useful information includes:
Cooling tower manufacturer
Cooling tower model
Fill pack width
Fill pack depth
Fill height
Number of fill layers
Existing fill type
This information helps suppliers determine the appropriate cooling tower fill replacement.
Tower Engineering is a U.S. cooling tower engineering and service company based in Fort Worth, Texas.
TEI works with permanent cooling towers for commercial, industrial, and power-generation applications and has experience with different cooling tower fill technologies, including PVC fill, ceramic tile, and high-performance ceramic fill.
TEI provides engineering, renovation, retrofit, and thermal-upgrade services involving fill selection and installation.
TEI notes that PVC fill is subject to fouling and identifies Brentwood Industries as its preferred PVC fill supplier for TEI installations.
Therefore, TEI is particularly relevant to customers looking for cooling tower fill replacement and thermal upgrade services, rather than simply buying loose fill media.
American Cooling Tower is a U.S. cooling tower company with roots in the industry dating back more than 80 years.
The company provides cooling tower design, repair, maintenance, rentals, and parts services.
American Cooling Tower's specifications include PVC cross-fluted fill media designed for high heat-transfer performance. Its specifications also address fill installation and water-basin access requirements.
The company provides solutions related to:
Counterflow cooling towers
Crossflow cooling towers
Cooling tower parts
Replacement fill
Cooling tower repair
Maintenance
Custom cooling solutions
| Manufacturer / Supplier | Main Fill Type | Typical Applications | Replacement Fill |
|---|---|---|---|
| Brentwood Industries | Film, trickle, splash | HVAC, industrial, power | Yes |
| SPX / Marley | Film & splash | HVAC, industrial, power | Yes |
| BAC | Film/replacement kits | HVAC, industrial | Yes |
| Tower Components | Film & splash | HVAC, industrial, power | Yes |
| C.E. Shepherd | Cellular & splash | Industrial cooling | Yes |
| Cooling Tower Products | PVC film fill | HVAC & industrial | Yes |
| C.T.P. Manufacturing | PVC fill | HVAC & process cooling | Yes |
| Cooling Tower Systems | PVC fill packs | Crossflow & counterflow | Yes |
| Tower Engineering | PVC & ceramic solutions | Industrial & power | Yes |
| American Cooling Tower | PVC cross-fluted fill | Cooling tower systems | Yes |
Choosing the correct fill type is critical because different cooling towers have different thermal, airflow, and water-quality requirements.
Film fill spreads water into a thin film over the surface of corrugated PVC sheets.
Large heat-transfer area
High thermal efficiency
Compact design
Good air-water interaction
Suitable for many HVAC applications
Film fill is commonly used in both crossflow and counterflow cooling towers.
Splash fill uses bars, grids, or modules to break falling water into smaller droplets.
Good resistance to fouling
Suitable for poor water quality
Better tolerance of suspended solids
Suitable for industrial applications
Splash fill can be a good option when water quality makes conventional film fill difficult to maintain.
In a crossflow tower, air generally moves horizontally across the falling water.
Crossflow fill is commonly available in:
Hanging film fill
Cross-fluted fill
PVC film fill
Splash fill
Correct fill selection should consider the existing tower design and original thermal requirements.
Counterflow towers move air upward while water flows downward.
PVC film fill
Vertical-fluted fill
Cross-fluted fill
Low-fouling film fill
Splash fill
The correct flute geometry and spacing can influence heat transfer, airflow resistance, and fouling performance.
When comparing cooling tower fill manufacturers in USA, price should not be the only consideration.
Common materials include:
PVC
CPVC
PP
HPVC
Ceramic
PVC is widely used because it offers a practical combination of cost, thermal performance, chemical resistance, and manufacturability.
Water quality is one of the most important factors when selecting cooling tower fill.
High-efficiency film fill can provide excellent thermal performance.
Consider:
Low-fouling film fill
Vertical-fluted fill
Splash fill
Larger flute spacing
The objective is to balance thermal efficiency and fouling resistance.
Before ordering replacement fill, measure:
Fill height
Fill width
Fill depth
Sheet thickness
Flute spacing
Pack configuration
Do not select cooling tower fill based only on the cooling tower brand.
A replacement fill should be evaluated according to the tower's:
Water flow rate
Airflow
Hot-water temperature
Cold-water temperature
Wet-bulb temperature
Approach temperature
Heat load
A fill that physically fits the tower may not necessarily provide the required thermal performance.
Replacing old fill can be an effective way to restore cooling tower performance.
Consider replacement when the fill shows:
Heavy scale buildup
Biological fouling
Broken sheets
Deformation
Clogging
Excessive sediment accumulation
Reduced cooling performance
Increased approach temperature
A cooling tower may show:
Higher leaving-water temperature
Reduced cooling capacity
Increased fan energy
Uneven water distribution
Increased pressure drop
Visible fill damage
Determine whether the existing fill is damaged, clogged, or simply dirty.
Measure the existing fill pack and document the tower configuration.
Determine whether the tower uses:
Film fill
Splash fill
Crossflow fill
Counterflow fill
Choose a product based on thermal requirements and water quality.
Ensure the fill is correctly supported and aligned to maintain designed airflow and water distribution.
After installation, check:
Entering-water temperature
Leaving-water temperature
Water flow
Airflow
Fan operation
Pressure drop
Approach temperature
PVC fills for cooling tower applications remain popular because PVC provides a useful balance of performance and cost.
Lightweight
Corrosion resistant
Easy to thermoform
Good thermal performance
Available in different thicknesses
Suitable for customized dimensions
Widely available for replacement projects
PVC fill is available in multiple designs, allowing manufacturers to optimize the balance between heat transfer and fouling resistance.
When purchasing replacement fill, buyers typically have two choices: OEM fill or aftermarket fill.
OEM fill is designed specifically for a manufacturer's cooling tower.
Original design compatibility
Known thermal characteristics
Model-specific fit
Technical documentation
OEM support
Aftermarket fill can be manufactured for many different tower brands and configurations.
Competitive pricing
Custom dimensions
Multiple fill designs
Suitable for obsolete towers
Flexible replacement options
The most important consideration is not simply whether the fill is OEM or aftermarket, but whether its thermal performance, dimensions, material, and installation configuration are suitable for the tower.
