If your keg cooler is separated from the bar by a long run of trunk line, size the glycol chiller from the complete system load, not horsepower or distance alone. Count faucets, measure the actual one-way trunk run, account for warm areas and future taps, then select a power pack with enough BTU capacity and the right number of pumps. An undersized unit can mean warm beer and foam during a busy shift. A unit selected without regard for the layout can create needless cost and service problems.
In this article
- What determines glycol chiller size?
- How do you measure a long draw system?
- Which trunk line size fits the run?
- How do you select the power pack?
- What sizing mistakes cause warm beer and foam?
- Frequently asked questions
What determines glycol chiller size for a long draw system?
BTU capacity is the number to start with. A glycol power pack removes heat from the glycol loop as it travels alongside the beer lines in the trunk line. The number of faucets, total trunk length, insulation, ambient heat, tower locations and desired room to expand all affect that heat load.
Micro Matic's draft beer power pack calculator makes the same point: calculate total BTU load rather than choosing by run length alone. Its trunk line guidance is a useful first screen: up to 50 feet typically uses 1/4-inch trunk line, up to 125 feet typically uses 5/16-inch, and runs up to 750 feet typically use 3/8-inch. Final selection should follow the power pack and trunk line manufacturer's current specs.
How do you measure a long draw system before sizing the chiller?
Measure the one-way route from the glycol power pack to the furthest tower. Do not use a straight-line measurement through the building. Follow the actual path through the walk-in, wall penetrations, ceiling, soffit or conduit. Mark every tower and count all faucets served by the same loop.
- Map the longest one-way run. Include the real routing, not just the distance on a floor plan.
- Count product lines and towers. A multi-tower job must be evaluated as one system, not as separate short runs.
- Note the environment. Hot kitchens, sun-exposed areas, poorly ventilated ceilings and unconditioned spaces raise the job's cooling demand.
- Confirm the pump circuits. One pump may be right for one loop. Separate runs or zones may call for two or more pumps.
- Leave a growth margin. If the bar expects to add taps or another tower, identify that now rather than replacing the power pack later.
SKU 826-MMPP4300-AB, for short glycol-chilled systems under 35 feet without much elevation change. Ships freight, not UPS Ground.
Which trunk line size should you use for a glycol-cooled beer system?
Trunk line needs to match the route and the number of product lines. The insulation and glycol circuit are as important as the beer line itself because the glycol loop is what protects beer temperature from the walk-in to the faucet.
| One-way run | Typical trunk line starting point | What to verify |
|---|---|---|
| Up to 50 ft | 1/4-inch trunk line | Faucet count, insulation and route heat |
| Up to 125 ft | 5/16-inch trunk line | Pump capacity and multiple tower routing |
| Up to 750 ft | 3/8-inch trunk line | BTU load, loop design and installer engineering |
This table is a starting point from Micro Matic's published calculator, not a substitute for an engineered equipment schedule. A longer run, high ambient heat or a larger number of faucets may move the job into a different power pack class even when the trunk line size looks familiar.
How do you select a glycol power pack after calculating the load?
Match the calculated load to an available power pack, then check pump count, bath capacity, electrical requirements, physical space and freight delivery before ordering. Do not choose a power pack only because it has a familiar horsepower label.
For example, the Micro Matic Pro-Line 3,600 BTU, 1/2 HP, two-pump air-cooled power pack lists an 11.5-gallon glycol bath and two pumps. That can make it a practical conversation starter for a layout that needs two circulation circuits, but the final choice still depends on the actual BTU calculation and design.
A 3,600 BTU air-cooled power pack with two pumps and an 11.5-gallon glycol bath for long draw layouts that need two circulation circuits.
For higher-load long draw work, the Pro-Line 5,100 BTU, 3/4 HP, two-pump air-cooled power pack has a 5,100 BTU rating, two pumps and an 11.5-gallon glycol bath. Both power packs ship by freight, not UPS Ground. That detail matters when you are scheduling an opening, replacement or installer visit.
A 5,100 BTU, two-pump power pack for long draw systems where the calculated cooling load calls for additional capacity.
What glycol chiller sizing mistakes cause warm beer and foam?
- Choosing from line length alone. Run length matters, but faucet count, heat exposure and circulation design also matter.
- Ignoring the furthest tower. A shorter first tower can pour well while the remote tower becomes the customer complaint.
- Forgetting future growth. Adding taps after the fact can turn a comfortable load into a constant-run problem.
- Confusing a brewery chiller with a beer line power pack. Fermentation and brite-tank cooling are different applications from maintaining beer temperature in a draft trunk line.
- Ordering a failed pump before diagnosing it. If the power pack is cold but the lines are warm, inspect circulation and the coupling before ordering a replacement assembly. For a confirmed failure, the 1/3 HP 105 GPA glycol pump and motor assembly is a direct-replacement option for most standard commercial power packs.
Related guides
- What You Should Know About Planning a Beverage System
- Fix Foamy Beer: Causes and Fixes for Draft Systems
- Shop glycol chillers and long draw system components
Need a second set of eyes on your long draw layout?
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Frequently asked questions
What size glycol chiller do I need for a long draw draft beer system?
Size the glycol chiller from the complete BTU load, including the faucet count, actual trunk line route, insulation, ambient heat and growth plans. Use the equipment manufacturer's calculator and confirm the final selection with the installer or draft technician.
How far can a glycol chiller run beer lines?
The maximum run depends on the power pack, trunk line, number of faucets and conditions. SKU 826-MMPP4300-AB is intended for short glycol-chilled systems under 35 feet without much elevation change. Longer or higher-load jobs need their own calculation.
What temperature should a draft beer glycol bath be?
The right glycol bath setting depends on the equipment and design. Follow the power pack manufacturer's operating instructions and use its digital thermostat or temperature control to keep the system at the specified setting.
Can one glycol power pack serve more than one beer tower?
Yes, if the combined BTU load and circulation design are within the unit's capacity. Count every faucet and tower on the loop, measure the real route to the furthest tower, and select enough pump circuits for the planned layout.
