Cooling Tower Fills: What Are They? And Who Uses Them?

Cooling Tower Fills

Cooling towers being the main means by which an industry or a home can regulate temperatures should be cost-effective and efficient in their work. Ineffective cooling tower parts can result in inefficiency use. Below in this article, you can find the Cooling Tower Fills.

Production may be stagnated and there may be a rise in the risk of high water temperatures as undesired. Cooling tower parts contributes to the hydrothermal cycle and should be of high quality when chosen.

The main aim of cooling towers is cool water quickly and efficiently. In order for them to achieve this, there is a need for water flowing over as much surface as possible. The objective is providing the maximum contact possible between the air and water. Cooling tower fills are used to increase the medium used to increase the surface area in cooling towers for the water to enhance evaporation.

What is a Cooling Tower Fill?

A cooling tower is a system that is made up of different components working together with the aim of regulating temperatures. The basic principle of a cooling tower is to lower the surrounding temperatures in a building. This function is achieved by interchanging the warm temperatures with lower temperatures from the atmosphere.

Cooling tower parts achieve this basic function by evaporating hot water and airflow to reduce the temperatures. This requires full optimization of water which is a scarce resource with many areas being supplied by urban tap water. Cooling tower fills ensures maximization in the utilization of this rare commodity.    

Cooling tower fills as cooling tower part are very important because they make hot water have much more surface area to enable quick cooling. When water is cooled it flows back into the tower releasing warm air into the atmosphere in a continuous cycle. This is achieved through the evaporation process.

Purpose of Cooling Tower Fills

The main purpose of cooling tower fills is to ensure cooling of water and full utilization of water in the system.  Cooling tower fills ensures the reduction in operating costs by providing an avenue for the cooling tower to treat and recycle water. Cooling tower fills are used to increase the surface area required for exposing hot water to air.

Classification of Cooling Towers Fills

There are two major classifications of cooling tower fills according to the principle used. They are categorized as follows:

Splash Fills

Cooling tower parts are many but the main part is the one used in ensuring that temperatures are regularized. Cooling tower fills fulfill this main aspect of cooling towers. Splash fills use the principle of ensuring that water cascades through a series of parallel bars. The bars cause the water to splash.  Since cooling tower fills with splash type ensures the least opposition to airflow especially in horizontal direction makes them very suitable for crossflow cooling towers. Splash cooling tower fills have the advantage of using water with debris because splashing action redistributes water at each level of the bars.

Splash fills increase the time of air and water contact as a result of repeated interruption of the flow of water.

The features for splash fills designs are:

  • Ideal where the source of water is dirty
  • Enhance ease redistribution of water
  • Good for the dusty and woody environment
  • Easy to maintain as compared to others
  • Provide longer service life
  • There designs available for heavy ice loads and high temperatures

Film Fill

The system provides sheets of materials shaped in a way that ensures travel of water across a pattern. The cooling tower parts can be made into blocks stacked together with the aim of creating thickness and heights fitting individual cooling tower. Film fill as a cooling tower part is limited in the redistribution of water in the cooling tower. Due to the narrow passage of the film cooling tower fill it makes it challenging to maintain.    

The key features of film fills are

  • They have a greater cooling capacity
  • Designs are available for a low clog
  • They come either with bottom or hanging design
  • Either available in crossflow or counterflow designs
  • Available even in high-temperature designs

Cooling tower fills can also be classified according to the flow of water and air. They re

Cross-corrugated fills

These cooling tower fills are very efficient but can easily foul in their operation. They offer maximum surface area. 

Vertical offset fills as cooling tower parts offer a maximum surface area for evaporation and cooling. They are efficient and are not prone to fouls. They also offer maximum surface area. 

Vertical cooling tower fills are the best for dirty water which may contain debris. These type of cooling tower fills is less susceptible to problems as compared to the others. They also have the lowest pressure drop.

Factors To Consider When Selecting Cooling Tower Fills

Film fill as cooling tower part is more efficient though susceptible to wear and tear because it is exposed more to water with high temperatures.

If you are using water of poor quality with high solids contents the best option is the splash fill media.

For water generated at a higher temperature, you should go splash media for a cooling tower fill.

The size of your cooling tower contributes much to the decision. Cooling tower parts are made to fit specific sizes and designs of towers.

Who Uses Cooling Tower Fills

Cooling tower fills manufactured by independent factories are meant for use by:

    • Designers of cooling towers in ascertaining the rating in performance.
    • Technicians engaged in repair of cooling towers as a recommendation for their clients
    • Structural engineers when building cooling towers.
    • Cooling tower owners when making decisions on replacement and recommendations according to their requirements.


  • Manufacturers of other cooling tower parts so as to ensure compatibility.



Fills are an integral part of cooling tower parts for ensuring optimal performance. Increased surface area results in more exposure thus cooling tower fills full this.

A cooling tower performance will be affected by the choice and design of the fill it uses based on its size, water used and the mechanism used in inducing evaporation.