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Opti-Bar splash fill is a product developed by Tower Components, Inc. in 1993, for crossflow and counterflow cooling tower heat-transfer applications. It has been installed in cooling towers servicing electrical generating plants, refineries, steel and aluminum mills, chemical plants, food processing plants, gas liquefaction processors, sugar mills, and air conditioning applications. Opti-Bar splash fill provides optimum performance, optimum strength, and optimum versatility. Our installation list contains numerous repeat customers.

Splash fills maximize the water-surface-to-air interface. Instead of sheet surface, splash fills increase the water droplet surface. The splash fill breaks the water into smaller droplets, continually exposing more water surface to the airflow. The splash fill also allows the water to stay suspended allowing greater time exposure to the air. Historically, splashing fills have been made of a wood lath matrix or other forms of PVC or Polyethylene.

Principle of Operation Splash Fill

In a major research study conducted in 1999 by an independent cooling tower consultant published as CTI Technical Paper TP 05-99, titled "A Comparison of Crossflow Cooling Tower Splash Type Fills", Opti-Bar was tested against a number of other splash fills available at the time of the study. The test results showed that Opti-Bar was at least 10% more efficient than the nearest competitive splash fill design.

The tubular-design configuration allows Opti-Bar to be secured in the wire mesh supports and held firmly in place without the use of additional support pads/fastening clips, which are commonly required on other splash fill designs. Opti-Bar is manufactured to a nominal width of 4-1/8”, and height of 1-1/4”. When it's installed in standard wire mesh hangers, the 4-1/8” wide bar compresses slightly to secure itself in place and no additional supports or attachments are required. As an option, Opti-Bar can be manufactured to a 3-5/8” width to fit plastic mesh fill supports. This design eliminates the streaming and channeling of water common with standard bar fills. The open areas between mesh strands allow water droplets to pass through the bar and be cooled by the air passing under the bar. The dead space, typically found under other bar fills, is a major design flaw that degrades tower performance.

Opti-Bar is manufactured from high-density polyethylene material, contains UV inhibitors, and are resistant to chemical and biological attack: acids, alkalis, and hydrocarbons. Opti-Bar can be used with 145° F continuously hot water temperature.

As an option, Opti-Bar is available with an ASTM E-84 rating of ≤ 25 using flame retardant additives.

  • Unique Design – Highly Efficient
  • Improves System Performance
  • Maximizes Air / Water Interface
  • For Crossflow and Counterflow Applications
  • Available in HDPE Material
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