Precision Cooling Simulation for Perfect Extrusion.

The internationally leading simulation software for the analysis and optimization of extrusion downstream processes. Reliably calculate product properties and improve quality for tubes, profiles, films, and sheets.

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  • Perfect extrusion cooling
  • Reliable planning results
  • Expert support
Cooling simulation of a complex window hollow-chamber profile.
Industry References

Trusted Worldwide by Industry Leaders

Trusted by over 80 customers worldwide, chillWARE® is the leading choice for renowned companies like Krauss Maffei and Rehau to ensure maximum planning reliability in extrusion.

With over 150 successful projects, we help manufacturers eliminate defects like deformations and residual stresses, optimizing production speed while maintaining high product quality.

Our extensive database of over 200 materials serves as the foundation for realistic simulations, allowing for the precise calculation of cooling behavior across diverse polymer types.

Eliminate the Guesswork in Your Extrusion Line.

Stop relying on expensive trial-and-error on the production floor. chillWARE® answers your most critical engineering questions before a single meter of material is wasted

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  • How long must a cooling section be for your target velocity?
  • What coolant temperature achieves the best product properties?
  • How can you eliminate deformations, residual stresses, or wall thickness issues?
  • How much energy can you save by changing parameterization?
Features and benefits

A Tailored Module for Every Extrusion Challenge

chillWARE® offers a comprehensive suite of specialized modules designed to optimize every aspect of the plastic extrusion process.

PipeSIM

Simulation for mono pipes, including shrinkage and ovality analysis.

CoExSIM

Simulation for multilayer pipes, including shrinkage and ovality analysis.

ProfileSIM

Specialized for complex geometries with hollow chambers and internal air flow.

SheetSIM

Comprehensive view of chill rolls, coating, and lamination for films and sheets.

CableSIM & RodSIM

Precise thermal control for solid, rotationally symmetric products and cables.

SaggingSIM

Combined thermal and flow simulation to predict melt deformation in heavy wall tubes.

Data

Realistic Results Driven by Data.

The foundation of our realistic simulations is a powerful database of 200+ polymer materials. Need something custom? We can characterize your specific material in our lab and integrate it directly into your database.

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Simulation-Driven Excellence

Digital Twin of Extrusion Downstream

Transform your production line into a high-precision virtual environment to optimize performance and accelerate innovation before physical implementation.

Comprehensive Digital Modeling

Create a complete digital twin of your extrusion downstream and cooling line, integrating all relevant process parameters.

Precision Process Control

Define individual thermal boundary conditions for every section—including temperatures & heat transfer coefficients.

Risk-Free Virtual Testing

Virtually test new processes, materials, and technologies to refine your cooling line while reducing development time & minimizing risks.

See it in Action

Virtual Testing & Simulation Insights

Experience how chillWARE® visualizes complex extrusion processes through high-quality animations and results.

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Cooling simulation of a large pipe with an outer diameter of 1200 mm, including active internal air cooling to reduce sagging and internal stresses.
Simulation of the cross-linking process and the subsequent cooling process for a PEX cable
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Simulation of a medical multi-lumen catheter with air flowing through the lumens
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Cooling simulation of a multilayer film on a calender, including downstream coating on a second extruder.
Process

From Design to Insight in Minutes

With chillWARE®, simulating and optimizing your extrusion process is fast, intuitive, and highly efficient. Our high-performance engine moves you from initial design to deep production insights in just minutes.

01

Product Definition

Create geometries in the integrated designer or import via CAD for seamless engineering workflow integration.

02

Process & Line Setup

Set melt temperatures and build your downstream line step-by-step to perfectly mirror your real production setup.

03

High-Speed Simulation

High-performance engines deliver results within minutes, allowing you to move from setup to insight almost instantly.

04

Analyze & Optimize

Run multiple iterations to systematically optimize your process & generate professional reports or animations.

Client feedback

Trusted Worldwide by Renowned Industry Leaders

See how leading extrusion specialists use chillWARE® to optimize production speeds, reduce energy consumption, and ensure maximum product quality through precise cooling simulation.

Engineering Planning Security

chillWARE® lets us simulate cooling during design, ensuring high planning reliability and stable processes for our customers.

Hans Weber Maschinenfabrik

Resource & Energy Efficiency

Optimized cooling and tempering sections resulted in significantly reduced energy needs and better product quality.

Becker Plastics

Superior Process Stability

chillWARE® helps us design cooling sections to improve stability and production performance.

Wavin

Reliable Partner

chillWARE® reliably optimizes cooling to reduce ovality and internal stresses for consistently high product quality.

Gerodur

Support

We provide end-to-end support

SHS Plus brings decades of integration expertise to your chillWARE® deployment. We manage the technical details so you focus on what matters—running better production.

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FAQs

Frequently Asked Questions

Find quick answers to common questions about how chillWARE® optimizes extrusion cooling, supports various applications, and integrates into your production environment.

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chillWARE® is a powerful simulation software for designing, analyzing, and optimizing cooling processes in plastics extrusion. It supports 2D and 3D simulations for pipes, profiles, sheets, cables, rods, and more – helping manufacturers improve product
quality and production efficiency.

chillWARE® is used by:
  • extrusion line operators
  • process engineers
  • R&D and product development teams
  • machine and tooling manufacturers
  • Tool designers
  • Managing Directors
Anyone who wants deeper insight into cooling behavior and process optimization benefits from chillWARE®

Predict cooling behavior before production

  • Reduce trial-and-error on the extrusion line
  • Optimize cooling section design and length
  • Increase production speed while maintaining quality
  • Identify hot spots, cold spots, and residual stresses early

In short: better products, faster ramp-up, lower costs.

  • Intuitive operation, simple workflows
  • Fast simulation results
  • Physically based models proven in practice
  • Temperature-dependent material data
  • Detailed analyses and automatic reporting

This makes it highly practical and close to real production conditions.

Depending on the license, chillWARE® includes modules such as:

• PipeSIM / CoExSIM – mono- and multilayer pipes • ProfileSIM – solid and hollow profiles • sheetSIM – sheets and films • CableSIM, RodSIM – specialized extrusion products

Yes. chillWARE® is designed to simulate complex multilayer products, including co-extruded pipes, sheets, and profiles, with different materials and process conditions.
chillWARE® provides:
  • temperature profiles along the entire cooling line
  • hot spot and cold spot analysis
  • cooling gradients
  • shrinkage and residual stress evaluation
  • crystallization
All results are visualized clearly and can be exported for documentation.

Absolutely. Simulation results can be exported as:

  • automated Excel reports
  • detailed Excel or CSV data
  • high-quality graphics for presentations
  • animations

Perfect for internal reviews, customer discussions, or project documentation.

chillWARE® uses a flexible licensing system:

  • local licenses
  • network (floating) licenses
  • optional offline usage via temporary license detachment

This allows easy integration into existing IT environments.

No. chillWARE® does not require a permanent internet connection during operation.
This can usually be explained by:
  • incorrect input units or assumptions
  • differences between measured and actual melt temperature
  • wet product surfaces or strong air flow increasing heat transfer
  • material behavior such as crystallization effects
With correct input data, chillWARE® delivers highly realistic results.

Perfect Your Extrusion Process

Reliably calculate product properties and improve quality using specialized simulation software for all your downstream cooling needs.

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