comparison between Film Fill/Splash Fill and PVC/PP Fill Sheets used in cooling towers and other heat exchange applications:
1. Film Fill (Splash Fill)
- Material: Typically made from PVC (Polyvinyl Chloride) or PP (Polypropylene) in thin, corrugated sheets.
- Design:
- Film Fill: Creates a thin film of water to maximize surface area for heat transfer.
- Splash Fill: Uses staggered bars or grids to break water into droplets for evaporative cooling.
- Applications:
- Film Fill: Used in counterflow cooling towers (water flows downward, air flows upward).
- Splash Fill: Common in crossflow cooling towers (water falls vertically, air flows horizontally).
- Advantages:
- High thermal efficiency (especially film fill).
- Lightweight and cost-effective.
- Good resistance to scaling and fouling.
- Disadvantages:
- Prone to clogging in dirty water conditions.
- Less durable under high-velocity water flow.
2. PVC/PP Fill Sheets (Structured Packing)
- Material: Made from rigid PVC or PP sheets with engineered patterns.
- Design:
- Structured, honeycomb-like or corrugated patterns.
- Optimized for both film formation and splash effect.
- Applications:
- Used in industrial cooling towers, chemical processing, and HVAC systems.
- Suitable for both counterflow and crossflow designs.
- Advantages:
- Higher mechanical strength than standard film fill.
- Better resistance to chemical corrosion (especially PP in aggressive environments).
- Longer lifespan in harsh conditions.
- Disadvantages:
- More expensive than basic film/splash fills.
- Heavier, requiring stronger support structures.
Key Differences
| Feature | Film Fill / Splash Fill | PVC/PP Fill Sheets |
| Material | Thin PVC/PP films | Thicker PVC/PP sheets |
| Efficiency | High (film fill) / Moderate (splash) | High (structured design) |
| Durability | Moderate (can deform) | High (rigid structure) |
| Clogging Risk | Higher (thin gaps) | Lower (wider flow paths) |
| Cost | Lower | Higher |
| Best For | Clean water, HVAC | Industrial, harsh conditions |
Which One to Choose?
- For high efficiency & clean water → Film Fill (cost-effective).
- For dirty water & heavy-duty use → PVC/PP Fill Sheets (durable, anti-clogging).
- Chemical resistance needed → PP Fill Sheets (best for corrosive environments).