Glycol Power Pack Replacement: Cost Drivers and Options
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Updated October 14, 2026
Quick answer
The cost of replacing a glycol power pack depends on its capacity (how many lines and how long the run), the brand, whether the trunk line can be reused, and the labor to drain, swap and recharge the system. A failed pump or fan motor is usually worth repairing; a failed compressor on an old unit often is not.
What drives the price
- Capacity: number of draft lines and trunk length
- Brand and model: Perlick, Micro Matic, Glastender, UBC and others
- Location: basement, storeroom or roof, and how hard access is
- Trunk line condition: reusing a good trunk saves a lot
- Glycol: new food-grade glycol to refill the system
Repair or replace
| Failure | Usual call |
|---|---|
| Pump motor | Repair |
| Condenser fan, controls, probe | Repair |
| Refrigerant leak on a newer unit | Repair |
| Compressor on an old unit | Compare with replacement |
| Undersized for added taps | Replace with a larger pack |
Before you replace
Have the refrigeration side diagnosed. Many "dead" power packs have a dirty condenser or a failed fan. See glycol power pack problems.
Downtime planning
A power pack swap means draining and refilling glycol and bleeding air from the trunk. Plan it for your slowest day, and confirm the replacement unit is in stock before the old one is disconnected.
Sizing a power pack
Power packs are rated by cooling capacity (BTU per hour) and pump count. Micro Matic's Pro-Line range, for example, runs from about 1,700 BTU with one pump to larger multi-pump units; Perlick's 4410 and 4420 packs come in air- and water-cooled versions with one to three 100 gph pumps. The right size depends on the number of lines, trunk length, the temperature where the trunk runs and future taps. Undersized packs run nonstop and still pour warm.
| Factor | Effect on size |
|---|---|
| More draft lines | More heat to remove |
| Longer trunk | More heat gain along the run |
| Trunk through warm spaces | More heat gain |
| Multiple bars or towers | More pumps or circuits |
| Planned expansion | Spare capacity now |
Owner checks before you replace
| Step | Check | What the finding means |
|---|---|---|
| 1 | Condenser fins | Dirty: clean first; many "dead" packs recover |
| 2 | Pump running, glycol returning | No flow: pump repair, not replacement |
| 3 | Bath level and ice | Ice or low level: control or mix |
| 4 | Age and refrigerant on the data plate | Old unit plus compressor failure: compare replacement |
| 5 | Taps added since installation | Undersized: replace with larger |
What a replacement involves
- Drain glycol from the bath and lines.
- Disconnect and remove the old pack; recover its refrigerant.
- Set and wire the new pack on the right circuit.
- Connect supply and return lines; fill with the manufacturer's glycol mix.
- Bleed air, start up, and verify bath and faucet temperatures.
Maintenance that extends life
The Brewers Association manual calls for monthly condenser, pump and motor checks, bath temperature every two weeks, and glycol testing every six to 18 months. Packs maintained on that schedule last longer and fail less often on weekends.
Bay Area factors
Rooftop packs in hot inland cities and basement packs in poorly ventilated San Francisco buildings both shorten equipment life. Moving a pack to a better location during replacement can be worth the extra work.
Cost of running an undersized or failing pack
A pack that runs nonstop uses more electricity, wears its compressor and pump faster, and still lets beer warm on the way to the tap. Foamy pours mean wasted beer on every pour. When a bar adds taps or extends a trunk, the original pack is often the hidden reason pours got worse.
Refrigerant rules
Glycol power packs are self-contained refrigeration units. When you buy a new one, ask what refrigerant it uses and confirm it meets the EPA rules for its category at the time of purchase. Existing packs can keep running and be repaired.
Questions to ask before buying a new pack
- What capacity do my lines, trunk length and location need?
- Air-cooled or water-cooled for this location?
- How many pumps, and do I need separate circuits for multiple bars?
- What refrigerant does it use?
- What warranty does the manufacturer offer?
- Can the existing trunk line be reused?
Bay Area installation notes
Many Bay Area bars put packs on roofs or in basements because space is tight. Rooftop installs may need a crane or extra labor; basement installs need ventilation. Electrical upgrades in older buildings can add cost; check the circuit the new pack needs before ordering.
When to call a technician
Get a refrigeration diagnosis before buying a new power pack; many failures are repairable.
Open 7 days, 8 AM to 5 PM, with emergency service until 9 PM. CA Lic. #776244.
Frequently asked questions
How long does a glycol power pack last?
It varies with use and location; keeping the condenser clean is the biggest factor we see.
Can I add taps to my existing power pack?
Only if it has spare capacity. Adding lines to an undersized pack causes warm pours.
Who replaces glycol power packs?
A refrigeration contractor, often working with your draft-service company on the beer side.
Can a water-cooled pack replace an air-cooled one?
Sometimes, where a suitable water supply and drain exist; it changes maintenance needs.
How long does a power pack replacement take?
Often a day of work once the new unit is on site, plus time to bleed air and confirm temperatures.
Does a new pack need a new trunk line?
Not if the trunk is in good condition and sized correctly.
Can you move a power pack to a better location?
Often, during replacement; it may require longer supply and return lines.
Is a used power pack a good idea?
Only with known history and capacity; a used pack of the wrong size causes the same warm pours.
Does a new power pack need a permit?
Usually not for a like-for-like swap; electrical changes may need one. Check with your city.
Related guides
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