Pillow Plate Heat Exchange Systems

Pillow plate heat exchange systems are based on double-profiled thermal sheets (called pillow plates), which, through variably welded constructions, provide a large, structured surface for heat transfer. Unlike conventional shell-and-tube or plate heat exchangers, pillow plate systems offer maximum flexibility in terms of form, size, and material and can be tailored to each process’s requirements. They are especially efficient with problematic media and provide minimal clogging tendency and easy cleaning, as the media flows over the large, low-resistance corrugated surfaces. These systems also feature high resistance to pressure and temperature fluctuations without sacrificing stability, combined with very high k-values due to the minimal pressure drop and enlarged surface area.

The principle is based on two separate flow paths for different media within cavities between the corrugated pillow plates. The large profiled surface enables a high heat flux (liquid/liquid or gas/liquid). The plate contouring ensures strong turbulence, enhancing heat transfer and reducing deposits. The system can be designed with a buffer volume or automated control to offset temperature peaks and load variations, ensuring stable and safe process management even with dynamic operating conditions.

Pillow plate systems are extremely flexible and can handle essentially all conventional industrial media, such as water, steam, thermal oils (for heating/cooling), brines, refrigerants (e.g., ammonia), process gases, as well as sludge-laden, viscous, or heavily soiled liquids from wastewater, biomass, or paper processing. Even aggressive, adhesive, or abrasive media are manageable due to robust construction and specialized corrugation, with extended cleaning intervals and simplified maintenance.

Industries include: 

• Paper and pulp: energy recovery from condensate and process steam, condensation and energy savings with high-volume flows
• Food industries: pasteurization and cooling of liquids, ice water production (e.g., dairies), flake ice for food processing
• Chemical, pharmaceutical industries: process cooling, solvent condensation, handling of particle-laden process flows
• Wastewater/environmental: heat recovery from exhaust air, industrial effluent, biomass processes

Advantages are always high energy efficiency, low operating costs, flexible design options, and safe handling of even very contaminated or difficult media.

Pillow plate systems are usually designed as open types, so plates can be individually inspected, cleaned, or replaced as needed. Open construction ensures optimal maintenance access, and stubborn deposits or fouling can be cleaned quickly and effectively. The smooth, corrugated surfaces foster self-cleaning by flow effects, which extends intervals and reduces labor and downtime.

Full-welded stainless steel construction and customized channels and wall thicknesses make the systems extremely robust and durable. Operational reliability is achieved through very low pressure drops and the ability to balance temperature/flow fluctuations with buffer tanks or control. The large surface area, targeted flow management, and optimized free channel cross-sections guarantee high energy efficiency.

Pillow plate systems are highly customizable: 

• Power range: individual systems from 10 to over 1,000 kW (up to 2.4 MW for large cooling units) 
• Plate sizes: up to 4,000 × 2,000 mm
• Wall thickness: 0.8/0.8 mm to 3/3 mm
• Operating pressures: standard up to 20 bar, special construction up to 50 bar
• Media: compatible with all common heat carriers (water, brine, gases, ammonia, thermal oil) 
• Design: as rolled cylinders, plates attached to round vessels, compact plug-and-play units, or system integration into existing tanks
• Channel layout and system configuration are individually engineered by experienced engineers.

They enable almost loss-free recovery of process heat from exhaust gases, vapors, and liquids, even when heavily contaminated. The recovered energy can support other process steps or building heating, reducing the need for external energy. This leads to substantial cost savings, improved CO₂ balance, and helps meet sustainability targets, especially in sectors like paper, biomass, and food processing.

For processes with fluctuating volumes and temperatures (e.g., food industry, tank farms), pillow plate systems act as a buffer by employing part of the heat/cooling medium volume, thereby mitigating sudden temperature changes and load spikes to maintain stable process conditions. The high specific surface area of the corrugated plates guarantees efficient heat transfer even with variable flows.

For media with high solid content or strong contamination (e.g., wastewater, biotech, or biomass processes), open pillow plate systems feature large, accessible channels, making inspection, cleaning, or even automatic flushing straightforward. Blockages, fouling, or scale formation are rare and can be further minimized by custom channel designs and targeted flow management.

Yes, pillow plate heat exchangers can act as evaporators for all conventional refrigerants, such as ammonia (NH₃), CO₂, R1234yf, and more. Low internal volume and a high surface area ensure rapid evaporation and high energy yield. PLC controls allow for precise temperature stabilization – for instance, producing ice water at +0.5°C for the food or pharmaceutical industries.

These systems excel at condensing process condensate and solvents (e.g., methanol, ethanol). Plate geometry and individualized channel layout enable stable, energy-efficient recovery and condensation, even with high vapor concentrations. The condensed liquid can be reintegrated into the process, supporting circular economy and resource efficiency.

In the pulp, paper, and chemical industries, where aggressive or high-temperature media are common, pillow plate exchangers’ corrosion-resistant stainless steel construction allows them to function as heating or cooling registers directly inside reactors or tanks. High operating pressures (up to 50 bar in special versions) are possible, enhancing process safety.

Yes, for air drying and filtrate recovery, pillow plate systems provide a compact, powerful alternative to traditional devices. Their open design, targeted air flow, and adaptable plate sizes enable energy-optimized drying and heat recovery, even with moist or contaminated gas streams, as in the paper or filtration industries.

Modular, customizable design means pillow plate systems can be integrated into existing tanks, reactors, or industrial facilities with ease – as rolled cylinders, special plates, or insertion registers, they flexibly adapt to on-site conditions. Integration with control and regulation systems (such as PLC) is also straightforward.

For processes needing high temperatures or special chemical properties (e.g., industrial furnaces or food processing), pillow plate exchangers can operate with thermal oils, brines, and specialized liquids, supporting a wide array of thermal applications such as interchangers, storage solutions, or targeted cooling/heating of specialty media.