Engineered Solutions
Thermo-Pack®
Engineered for your facility, not pulled from a catalog.
Most steam-to-hot-water systems make you design around them. This one is built around you.
Thermo-Pack is a compact, skid mounted shell and coil heat exchanger in 316L stainless steel — sized to your space, piped to your spec, with the controls you actually want. Same hot water. Less steam.
- Built to your facility: orientation, sizing, and controls to spec
- 10–15% energy savings vs. standard shell & tube
- A partner that picks up the phone with real, human support
- Low maintenance 316L SS heat exchanger, 5-year warranty
ENGINEER SHORTCUTS
What's in the Skid
A complete steam-to-hot-water system, on one skid.
Most heat exchangers make you design around them. This one is designed around you.
Thermo-Pack® takes steam and makes hot water, for domestic use or for heating, in a single skid-mounted package. We build it to fit the room you have: the right size, the connections where you need them, and the controls your team wants to run.
It shows up pre-piped, pre-wired, and ready to start-up.
- 316L stainless shell & coil heat exchanger. Fully welded, no tube sheet, no bundle to pull.
- NEMA 4 control panel. BACnet, Modbus, or LON integration.
- V-ball steam control valve. 300:1 turndown, up to 300 PSIG (often eliminates the PRV).
- Inlet wye-strainer, recirculating pump, base plates & supports.
- Pressure/temperature relief valve and steam safety shut-off.
- PID temperature control. Accurate to ±4°F.
Built for Your Facility
We can customize just about anything to fit your heating needs. Tell us about your steam load, footprint and challenges and we will configure the rest around it.
- Pressure-motive or pump traps
- Air and dirt separators
- Electric or pneumatic control valves
- Bio-Kill UV for Legionella defense
- Mixing valves
- Outlet orientations
- Equipment elevations
- Connection points and footprint
- Skid layout for the access you have
Why Thermo-Pack
Engineered to do
More with Less.
Thermo-Pack is built for your mechanical room, not pulled off a shelf. Every unit is customized to fit the space, install cleanly, cut maintenance hours, and help you hit sustainability targets without redesigning the whole system. Same hot water, less steam, less maintenace.
Built to Fit
Engineered to Spec
Custom-engineered around your facility’s footprint, piping layout, steam conditions, and operational requirements to simplify installation and fit the way your system actually runs.
Up to 15%
Energy Savings
Save 10–15% more energy compared to traditional shell & tube heat exchangers thanks to advanced sub-cooling that eliminates flash steam and maximizes energy utilization.
316L SS
Reduce Maintenace
Fully welded 316L stainless steel construction resists corrosion, scaling, and condensate-related wear that shorten the life of traditional shell & tube equipment.
SubCooling
Recover More Heat
Lower condensate temperatures help improve steam efficiency while reducing stress on downstream condensate and boiler system components.
Energy Savings & ROI
See the steam you'd stop wasting.
Traditional units vent flash steam. Thermo-Pack subcools the condensate and recovers the BTUs. How much you save depends on your system, but the comparison is consistent.
| Metric | Thermo-Pack® | Shell & Tube |
|---|---|---|
| Avg. condensate temperature | ||
| Steam consumption | ||
| Sub-cooling energy recovery | ||
| 4-week savings | Baseline | |
| Efficiency increase | Baseline |
Common Questions
What facility teams and engineers ask first.
Explore common inquiries about the installation, maintenance, and compatibility of our Thermo-Pack heat exchangers.
What makes the Thermo-Pack efficient?
The Thermo-Pack is designed to extract the maximum amount of usable heat from every pound of steam. Its cross-counterflow heat exchanger design maximizes heat transfer, while subcooling the condensate before it leaves the unit. This reduces flash steam, recovers more energy from the steam, and improves overall system efficiency. The result is lower energy consumption, less wasted steam, reduced wear on condensate return equipment, and lower operating costs compared to conventional steam-to-water heat exchangers.
How do you clean a Thermo-Pack Skid?
Cleaning a Thermo-Pack is straightforward. The heat exchanger is constructed from corrosion-resistant 316L stainless steel and includes 3/4-inch threaded cleaning ports on the water side for easy access. Depending on your water quality and maintenance program, the system can be chemically descaled or flushed to remove mineral buildup and maintain heat transfer efficiency. Regular preventive maintenance helps maximize performance, reduce energy consumption, and extend the life of the equipment.
What is the Maximum GPM the Thermo-Pack can handle?
There is no fixed maximum GPM for a Thermo-Pack. Every system is custom engineered to meet your required flow rate, temperatures, steam pressure, and pressure drop. Standard systems can be designed for applications ranging from small domestic hot water loads to large heating and industrial process systems handling hundreds of gallons per minute. For higher flow requirements, multiple Thermo-Pack heat exchangers can be manifolded together, providing virtually unlimited system capacity, built-in redundancy, and the flexibility to expand as demand grows.
Is the Thermo-Pack condensate controlled?
No, the Thermo-Pack uses steam-side controls. It includes a V-ball control valve with a 300:1 turn-down ratio, offering precise temperature control and eliminating the need for condensate-side controls. This design results in improved accuracy and energy savings.
What is the lead time for a Thermo-Pack?
Lead times depend on the size and configuration of your Thermo-Pack, as well as project requirements and drawing approval. Most standard systems are typically shipped within 8–12 weeks after approved submittals. If your project is on a tight schedule, expedited manufacturing may be available for select configurations.
How does Thermo-Pack's shell-and-coil design save energy and reduce maintenance?
Thermo-Pack lead times vary based on system size, controls package, and project requirements. Most standard systems are typically delivered within 8–12 weeks after submittal approval. Expedited options may be available for select configurations. Contact our team with your project details for the most accurate lead time estimate.
What warranty is included with a Thermo-Pack?
Every Thermo-Pack includes a 5-year warranty on the 316L stainless steel heat exchanger. All other skid components are covered by a 12-month warranty from the date of shipment or 18 months from the date of manufacture, whichever occurs first, in accordance with the component manufacturers' warranty terms. Contact our team for complete warranty details for your specific configuration.
What support is offered for setup?
Our team provides comprehensive support during the factory startup process to ensure your facility's heat exchanger is installed and operating efficiently. Our experts will be on-site to guide the process and address any technical concerns.
How much does the Thermo-Pack cost?
The cost of a Thermo-Pack depends on options, size, and configuration. For personalized quote on your project, contact our sales team at sales@cooneytechnologies.com or call (610) 783-1136 for a free quote.
Let’s Get Your Project Started
Whether you have a question, want to set up a lunch and learn, or you're ready to request a quote — our team is here to help.