The Hidden Costs of "Cheap" Coils

In the world of commercial and industrial heating and cooling coils, it can be tempting to focus solely on the upfront cost. When a coil needs to be replaced, the lowest bid can look appealing on paper. However, a seemingly “cheap” coil when purchased will most likely become a much more expensive coil over its lifespan – and cost more in the long run compared to a high-quality, custom-built Marlo coil.

While we understand that budget is always a consideration, a purchasing decision based purely on the initial price of a commercial or industrial coil typically overlooks two critical factors that come with a coil made by Marlo:

Long-term energy savings through superior heat transfer
Extended lifespan through quality construction

Let’s dive into why investing in a better-designed and better-built coil from Marlo Coil is a smart financial decision that pays dividends for years.

The True Cost of a Coil: Initial Price Plus Energy Usage Over its Lifetime

The primary job of a cooling coil or heating coil is to transfer heat efficiently. Whether it’s an HVAC coil for the comfort of a building’s occupants or an industrial coil for a critical production process, the coil’s performance as it maintains the required air temperature directly impacts the heating or cooling system’s energy consumption. In other words, a less efficient coil costs more money every single month of its life in increased energy bills.

That’s why it’s so important to have a coil that was engineered and manufactured for optimal heat transfer – and one that was designed for a specific application. There are so many variables that go into coil design: size, number and depth of tube rows, fin and tube material selection, and so much more. The bottom line is that an off-the-shelf coil will never operate more efficiently than a coil that was designed and built for a specific environment. A more efficient coil means:

Less stress on the system: More efficiency means that chillers, boilers, compressors and pumps don’t have to work as hard or as long to achieve desired temperatures.
Reduced run times: Fans, compressors, and pumps operate for shorter periods, directly translating to lower energy consumption – and cost savings.
Precise temperature control: A well-designed coil maintains set points more accurately, avoiding energy waste from over-cooling or over-heating.

A coil built that’s not sized and designed specifically for its application, or one built with shortcuts – perhaps thinner tube walls, less fin surface area, and/or less effective fin-to-tube bonding – will have inferior heat transfer characteristics. Naturally, that leads to a series of potential issues that can cost money month after month:

Increased run times: The system has to run longer to maintain the desired temperatures, burning more energy every hour of operation.
Higher operating costs: Over months and years, these incremental increases in energy usage add up to substantial added expenses, which can often go unnoticed.
Lower performance: Inefficiencies can also lead to comfort complaints or compromised processes, forcing you to push the system harder, further escalating energy use.

The Durability Dividend: Quality Construction Means Years of Extended Life

Beyond efficiency, a coil’s lifespan is a critical component of its true cost. Most people would agree that it’s not a good business decision to save 10% on a product that has 50% less lifespan. Yet choices like that are made far too often when it comes to commercial and industrial coils. Plus, the cost of a replacement coil itself is only part of the equation. Other factors like labor costs, downtime and shipping fees should also be considered. Not to mention that a sudden coil failure can lead to extra fees for expedited production and rush delivery.

Needless to say, choosing a heating or cooling coil that is built to last will result in less frequent replacement and long-term cost savings. Quality coils, like those we produce here at Marlo, are constructed with robust materials and meticulous attention to detail. Our focus on quality includes:

Thicker copper tube walls: Our standard .025” thick tubes (25% thicker than many of our competitors) are more resistant to erosion, corrosion, and pressure fatigue.
Durable fin stock: Marlo aluminum fins are typically .010” thick, or even 0.20” thick for heavy duty applications, making them far less prone to damage than the .0075” fins often used by other manufacturers.
Heavy duty box headers: Our coil box headers are fully welded and made of high-grade materials to withstand system pressures and thermal cycling.
Superior fin-to-tube bond: Reliable tube expansion into the fins assures maximum heat transfer and prevents premature failure due to vibration or expansion/contraction.
Expert brazing: Our experienced, certified brazers assure strong, reliable joints that offer maximum leak protection.
Robotic welding: Computer-controlled robotic welding machines offer the ultimate in precise and durable welds.
Corrosion-resistant coatings: A range of coatings are available for harsh environments, extending coil life significantly.
AHRI Certification: We offer chilled water and hot water coils that are performance-tested and certified by an independent third-party lab, assuring the performance of your coil matches what is promised by our MarloMetrics software. Many coil manufacturers do not have this critical certification, allowing them to over-promise and under-deliver. Learn more on the AHRI website.

The Marlo Coil Advantage: True Value Over Time

At Marlo, our commitment to superior design and quality construction means you get coils that provide better heat transfer and thermal efficiency, reducing your energy costs month after month after month.

Plus, our quality materials and construction processes mean your coils will last longer, giving you years of reliable service. That not only saves you money in replacement costs, but also eliminates the disruptions, downtime and labor costs of frequent coil replacement.

The bottom line is, don’t let a low upfront price mislead you. When it comes to commercial and industrial coils, true economy lies in quality, efficiency, and longevity. Even if the initial cost of a Marlo coil is slightly higher than a competitor’s product, the total cost of ownership over the life of the coil will almost certainly by less with Marlo.