Views: 0 Author: jessi Publish Time: 2026-09-03 Origin: Site
Cooling tower fill is one of the most important components in an evaporative cooling system. It increases the contact area between hot water and air, allowing heat to transfer more effectively through evaporation. The quality, design, material, and condition of the cooling tower fill can have a direct impact on cooling capacity, water consumption, pressure drop, and operating efficiency.
The UK has a well-developed cooling tower and industrial process-cooling market. Customers can source cooling tower fill from original equipment manufacturers, specialist cooling tower companies, replacement-parts suppliers, and international manufacturers with UK distribution or service capabilities.
Cooling tower fill, also called cooling tower fill media, is the heat-transfer material installed inside a wet cooling tower.
Hot circulating water is distributed over the fill surface while air passes through the fill. The fill spreads the water into thin films or breaks it into droplets, increasing the air-water contact area.
High-quality cooling tower fill can:
Increase air-water contact area
Improve heat-transfer efficiency
Increase water residence time
Reduce the required tower footprint
Support stable cooling performance
Help reduce operating costs
For this reason, selecting the right cooling tower fill media is essential when designing a new tower or replacing old fill.
The following companies and brands are worth considering when sourcing cooling tower fill and replacement fill for UK cooling tower 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.
Hewitech is an important specialist in cooling tower components and fill media.
The company states that it designs and manufactures cooling tower components and fills in the UK for natural-draft towers, packaged units, and field-erected cooling towers. Its products include PP and PVC fills, crossflow film fills, trickle fills, low-fouling fills, and related drift eliminators and air inlet louvers.
Its product range includes:
Crossflow film fill
Crossflow fill packages
High-performance trickle fill
Low-fouling fill
Vertical-fluted fill
PVC cooling tower fill
PP cooling tower fill
Hewitech products can be used in:
Power generation
Petrochemical plants
Industrial cooling
HVAC systems
Process cooling
Cooling tower refurbishment
Cooling Parts & Services Ltd is a UK-based specialist supplying cooling tower components and replacement parts.
The company provides heat-transfer fill in PVC and polypropylene for both clean and polluted water applications. It also offers close-packed film fill for packaged cooling towers and more open matrix fill for industrial applications.
High-efficiency film fill is suitable for applications where the circulating water is relatively clean.
Splash grid fill can be considered for systems with higher suspended solids or difficult water chemistry.
This makes Cooling Parts & Services a useful option for customers looking for cooling tower fill replacement UK solutions.
Eng-Tech Solutions provides cooling tower engineering solutions and replacement components.
Its cooling tower fill range includes PVC and polypropylene media for clean and polluted water. The company also supplies close-packed film fill, open-matrix film fill, and splash grid fill for different operating conditions.
Its cooling tower fill solutions can be considered when a project requires:
PVC cooling tower fill
PP cooling tower fill
Film fill
Splash fill
Cooling tower refurbishment
Fill replacement and upgrades
For replacement projects, fill selection can be matched to tower configuration, water quality, airflow, and thermal requirements.
EVAPCO is a major international manufacturer of evaporative cooling equipment and heat-transfer products.
EVAPCO offers replacement fill for its own equipment as well as other manufacturers' cooling towers. Its published replacement-fill information states that fill can be supplied for equipment from manufacturers including BAC, Marley, and Imeco.
EVAPCO's fill solutions include different designs for counterflow and crossflow applications.
EVAPCO fill can be considered when:
Existing fill is damaged
Fill is heavily scaled
Biological fouling has occurred
Fill has collapsed or sagged
Cooling performance has declined
EVAPCO notes that fill typically needs replacement once or twice during the life of a cooling tower, depending largely on water and air quality and operating conditions.
Baltimore Aircoil Company, commonly known as BAC, is another major cooling tower manufacturer serving industrial, commercial, and HVAC applications.
BAC cooling towers use engineered heat-transfer media designed to work with their water distribution and airflow systems.
BAC fill solutions are commonly associated with:
Counterflow cooling towers
Crossflow cooling towers
Industrial process cooling
HVAC applications
Replacement and refurbishment projects
When replacing BAC cooling tower fill, buyers should verify:
Tower model
Fill dimensions
Fill height
Flute geometry
Material
Water temperature
Water quality
Airflow direction
Correct matching is important because replacing fill with an unsuitable geometry can affect pressure drop and thermal performance.
Brentwood Industries is an established manufacturer of engineered plastic products and cooling tower fill solutions.
Its cooling tower media portfolio includes different film and splash fill configurations designed for industrial and utility applications.
Typical applications include:
Power plants
Industrial process cooling
HVAC systems
Utility cooling
Cooling tower refurbishment
Brentwood is particularly relevant for projects requiring engineered fill geometry and specialized solutions for different water-quality conditions.
When selecting Brentwood or equivalent fill, buyers should compare the fill surface area, flute configuration, material, water loading, thermal performance, and pressure drop.
Marley Flow Control provides cooling tower components and replacement parts for different makes and models.
Its cooling tower parts range includes film fill, splash fill, crossflow fill, counterflow fill, drift eliminators, louvers, nozzles, fans, gearboxes, and other mechanical components.
Marley Flow Control is particularly relevant to buyers looking for:
Replacement cooling tower fill
Crossflow fill
Counterflow fill
Film fill
Splash fill
Complete cooling tower refurbishment
This broad component portfolio can be useful when multiple cooling tower spare parts need to be sourced together.
Albion Cooling Systems Ltd is a UK cooling-system specialist with experience in air-conditioning and process-water cooling.
The company states that it is an independent equipment broker and can help customers find replacement parts for many cooling tower brands, including Evapco, BAC, Marley, and Carter.
Albion's independent approach can be useful when a customer needs to replace fill in an older or non-standard cooling tower.
Existing tower refurbishment
Replacement fill sourcing
Multi-brand cooling tower projects
Industrial process cooling
HVAC cooling systems
In addition to major OEMs, the UK market contains specialist cooling tower engineering and replacement-part companies that supply cooling tower fill media for different tower designs.
These suppliers can be particularly useful for older towers where original OEM fill is unavailable or expensive.
A specialist supplier may provide:
OEM-compatible fill
PVC film fill
PP fill
Splash fill
Custom dimensions
Replacement fill packs
Installation assistance
Cooling tower refurbishment
For older equipment, a custom-engineered replacement can sometimes be more practical than replacing the complete cooling tower.
Understanding different fill types is essential before choosing a manufacturer.
PVC cooling tower fill is one of the most common solutions for applications using relatively clean circulating water.
High heat-transfer efficiency
Lightweight construction
Good chemical resistance
Cost-effective
Easy to manufacture
Suitable for many HVAC and industrial applications
Film fill spreads water over a large surface area, increasing contact between air and water.
Polypropylene is another popular material for cooling tower fill.
PP can provide:
Good chemical resistance
Higher temperature capability than standard PVC in some applications
Good mechanical strength
Long service life
Suitable performance for industrial cooling
PP fill can be particularly useful when operating conditions exceed the recommended temperature range of standard PVC media.
Splash fill works differently from film fill.
Instead of forming a continuous water film, splash bars or grids repeatedly break falling water into smaller droplets.
Dirty water
High suspended solids
Industrial process cooling
Systems with higher fouling potential
Applications where film fill may clog easily
| Feature | Film Fill | Splash Fill |
|---|---|---|
| Heat-transfer efficiency | High | Moderate to high |
| Water quality requirement | Relatively clean | More tolerant |
| Fouling resistance | Lower | Higher |
| Surface area | Very high | Moderate |
| Typical material | PVC / PP | PP / PVC / other materials |
| Typical application | HVAC, clean industrial water | Industrial and dirty-water systems |
Choosing the right supplier involves more than comparing prices.
The fill should match the existing tower design.
Before requesting a quotation, provide:
Cooling tower manufacturer
Tower model
Tower dimensions
Existing fill dimensions
Fill height
Sheet thickness
Fill type
Water flow rate
Hot-water temperature
Cold-water temperature
This information helps the supplier recommend the correct product.
Water quality is one of the most important factors when selecting fill.
For clean and properly treated water, high-efficiency PVC film fill may provide excellent heat-transfer performance.
For water containing high levels of suspended solids, a more open film fill or splash fill may be more appropriate.
PVC is often selected because of its balance of cost, thermal performance, and chemical resistance.
PP can be advantageous in applications requiring greater temperature or chemical resistance.
Do not select fill based only on material price. The supplier should confirm that the material and fill geometry are suitable for the actual operating conditions.
Cooling tower fill gradually loses performance because of scale, biological growth, dirt, chemical attack, deformation, and aging.
Look for:
Increased cold-water temperature
Reduced cooling capacity
Increased approach temperature
Visible scaling
Biological fouling
Broken or collapsed fill
Excessive pressure drop
Water bypassing the fill
Uneven water distribution
Replacing damaged fill can restore heat-transfer performance without replacing the complete cooling tower.
For many refurbishment projects, cooling tower fill replacement is therefore a cost-effective way to extend equipment service life.
When ordering replacement fill, buyers should not rely only on the tower brand.
A supplier will normally need:
Cooling tower brand
Cooling tower model
Existing fill type
Fill dimensions
Fill material
Fill thickness
Operating temperature
Water flow rate
Photos of the existing fill
Quantity required
Photos can help identify:
Fill geometry
Sheet arrangement
Support structure
Louvers
Drift eliminator integration
Existing installation method
This is especially useful for older cooling towers where the original model information may be incomplete.
Proper maintenance can extend the service life of fill media.
Scale and biological growth can quickly reduce the performance of film fill.
Regular water treatment helps minimize:
Scale
Corrosion
Biofouling
Sediment accumulation
During cooling tower maintenance, inspect the fill for:
Cracks
Deformation
Blockage
Sagging
Biological growth
Scale deposits
Blocked nozzles can create uneven water distribution. Poor distribution means some areas of the fill receive too much water while others receive too little.
Higher-efficiency fill is not always the best choice. In dirty-water applications, an overly fine flute configuration may be more vulnerable to fouling.
PVC and PP are two of the most common materials. The best material depends on water chemistry, operating temperature, fouling conditions, and tower design.
There is no single service-life figure. EVAPCO notes that fill may need replacement once or twice during the life of a cooling tower, with longevity strongly influenced by water and air quality and operating conditions.
In many applications, PP can be considered as an alternative, but the replacement should be evaluated for temperature, chemical compatibility, fill geometry, and thermal performance.
Aftermarket fill may be available, but compatibility should be carefully evaluated. For certain Marley towers, OEM specifications and certifications can be important. SPX specifically advises using genuine Marley MX fill where maintaining its FM approval rating is required.
Not necessarily. Film fill generally provides high heat-transfer surface area but requires relatively clean water. Splash fill is often more tolerant of suspended solids and fouling.
The UK market offers a wide range of options for cooling tower fill, from major OEMs such as Marley, BAC, and EVAPCO to specialist UK cooling tower fill and replacement-part suppliers.
When comparing the Top 10 Cooling Tower Fill Manufacturers in UK, buyers should consider more than price. Important factors include fill material, thermal performance, flute geometry, water quality, operating temperature, tower compatibility, delivery time, technical support, and replacement requirements.
