COOLING MODULES

The concept of Engine Cooling Modules has been ultimately prompted by global car producers to attain productivity and cost saving in vehicle assembly operations. An engine cooling module is simply an assembly of components, typically consisting of a radiator, condenser (A/C Type), intercooler and fan motor & shroud.

At present, KALE produces the whole range of heat exchangers and plastic injection parts as assembly components of engine cooling modules whilst sourcing other parts from its suppliers. This new range of engine cooling modules has been widely preferred by vehicle manufacturers in recent years and KALE has been well positioned to supply its customers with engine cooling modules over the last decade and so.

INTERCOOLERS

Intercooler, also known as charge air cooler, principally functions as an air cooling heat exchanger. Generally fitted with the turbo charged engines, intercoolers have been mainly utilized in trucks, buses, tractors and high performance vehicles. By the mid 1970's, intercoolers were first mounted on the turbo charged engines in a limited way. By the utilization of intercoolers, harmful fuel emissions are reduced significantly whilst engine performance is boosted and fuel economy is improved. This function is achieved by the reduction of air inlet temperatures from 120 °C to 200 °C while passing through the turbo charger and bringing it down to the level of an air outlet temperature, which is approximately + 40 °C above the ambient temperature for Euro I engines , + 25 °C for Euro II engines and + 15 °C for Euro III engines.

And today due to new environmental regulations on fuel emissions, particularly on heavy truck, bus and other commercial vehicles , vehicle manufacturers are required to install intercoolers with Euro series engines.

KALE INTERCOOLER is designed and manufactured to provide;

• High engine performance
• Fuel efficiency
• Improved torque power
• Reduced fuel emission
• Compatibility with Euro series green engines.

With the employment of an intercooler, exhaust emission is improved, engine efficiency is increased, fuel consumption is reduced. These improvements are achieved by means of cooling the air intake and lowering its thermal stress before allowing it to go thorough the engine.

At the outlet of turbo charger , air temperature rises up to 200 C°. Air enters into the intercooler and cools down to the level, which is approximately + 40 °C above the ambient temperature. Then cooler air enters into the engine again.

Manufacturers have been calling these air coolers with different names such as charge air cooler , intercooler . However air coolers are pricipally mounted in between the turbo charger and the engine, which is making the term INTERCOOLER widely accepted in the industry.

CONDENSERS

In recent years, there has been a growing market demand for vehicles equipped with air conditioning systems for improved driver and passenger comfort, consequently vehicle producers are nowadays manufacturing more air conditioned vehicles than ever before to catch up with the current market demand. KALE has therefore expanded its range of products by moving into production of condensers and aligned itself with the current market trend.

In 1998, KALE commenced mass production of condensers for air conditioning systems, under aluminium brazing (CAB) technology and started supplying to OEM customers in Turkey and abroad.

Condensers are an integral part of the air conditioning system and designed to condense and cool down the coolant gas which is circulated by a compressor in the A/C loop.

ENGINE COOLING RADIATORS

COPPER RADIATORS

Copper Core and Brass Tanked Radiators:

Since 1966, KALE has produced conventional type of copper core and brass tanked radiators and has been continuously improving its own production techniques for more refined and higher quality copper & brass radiators by integrating advanced methods of production and processes into its production lines. KALE has therefore gained an excellent reputation for its high quality products over the years.

Copper Core and Plastic Tanked Radiators:

The first generation of copper & brass radiators have been increasingly replaced with the new generation copper & plastic tanked radiators especially in the range of automobile and light commercial vehicle radiators in recent years. Inherently, the new generation copper radiators offer manufacturing cost advantage, arising from higher productivity in production and raw material optimization

ALUMINIUM RADIATORS
Aluminium Mechanical Assembly Heat Exchangers:

In keeping pace with the latest production technologies, KALE, signed a Technology Transfer Agreement with a reputable European Company in 1986, in order to produce aluminium mechanical assembly heat exchangers with plastic tanks. Acting upon the requirements of the Turkish car manufacturers at the time, KALE swiftly adapted this new production technology and commenced supplying engine cooling radiators and heater cores to the key car manufacturers in Turkey and also to some neighbouring countries.

Aluminium Brazing Heat Exchangers:

Since the end of 1996, KALE has been applying an advanced manufacturing technology known as aluminium brazing (CAB ) system to its production of aluminium brazed products, initially starting with intercoolers (CAC) and then progressing with engine cooling radiators, heater cores, condensers, oil coolers and alike. To this end, KALE has signed a number of Technical Licence Agreements with the most reputable companies in their field, thereby ensuring a swift application of new production and assembly techniques with high manufacturing standards as required by vehicle manufacturers in global markets.

FAN&SHROUD ASSEMBLY