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Product Range
Fin and Tube Heat Exchangers
Aluminum Heat Exchangers

Aluminum Tube & Fin Heat Exchangers

Aluminum Condensing Coils

Aluminum Evaporator Coils


Copper tubes v/s Aluminum tubes

Condensing Unit
Coating Services
Aluminium Heat Exchanger

Aluminum Tube and Fin Heat Exchangers
(Mechanically Expanded)

The most common design of a Heat Exchanger today is the fin and tube heat exchanger. Pole Star recommends a solution using aluminium fins and specific aluminium tubes, as an obvious alternative over the copper tube. As illustrated, the aluminium tubes are first inserted into a stack of fins. The tubes are pre-bended in hair-pin shape. After insertion, the tubes are expanded. The expansion secures the thermal contact between tube and fin. Afterwards, U-bends are brazed to the tubes.

Compared to a traditional HVACR copper tube/aluminium fin heat exchanger, this provides:

  • A lighter heat exchanger
  • Better corrosion resistance, due to a better galvanic balance of the materials
  • More cost-effective heat exchanger

Why Aluminum: Aluminium as a material has major benefits.

  • Cost
  • Weight
  • Corrosion
  • Heattransfer  
Aluminium as a material has major benefits that we can’t keep secret any longer. 
  • Price Aluminium remains one of the most cost-effective materials you can use, with outstanding properties which enable considerable savings – it is two-to-three times cheaper than copper - and significant technological improvements.
  • Performance Using aluminium in HVACR applications improves system weight significantly. You save space and, also, in the case of a brazed heat exchanger, refrigerants. Further, you will gain a highly corrosion-resistant material with suitable alloys.
  • Sustainability Due to its material properties, aluminium lasts longer than other materials when used in an appropriate way. More than that, we view the increased recycling of aluminium as important for resource preservation.
  • Manufacturing Aluminium keeps adding benefits at the manufacturing stage by presenting easy forming abilities.

To know more please see the Comparison tables of aluminum to copper tubes used in HVAC heat exchangers.


Aluminum Condensing Coils
This all aluminum fin and tube heat condensing coil does not only maximize the heat transfer rate, but will also prolonged the life of the condensing coil. The condenssing coil can also be made using hydrophilic

aluminum foil which will disperse the condensed water rapidly so

as not to be coagulated into dropets bridge, the result is to expand heat transfer area, speedup freezing and heating while avoiding making noise produced by resistance of airflow.

Pole star can also supply dip coated condensers with super hydrofobic properties which gives a life warranty of 10 years


  • for applications including storage, process, comfort cooling, steam distrubiting, preheat, boosters, reheat, duct heaters, process air and gas heaters, fluid process heat, glycol heating, hot water application and more
  • avaliable in all sizes shapes, capacities, circuit patterns, mainfolds, thread fittings on manifolds, fin / tube configurations
  • avaliable from 1 to 12 rows deep and from 6 to 21 fins per inch
  • for use with steam / hot water / chill water / hfc's and non hfc's
  • manifold / connection ends of copper for easy installation / copper to copper brazing  in the system.

Aluminum Evaporator Coils
We are specialized in manufacturing Brazed Evaporator Coils using Aluminum tubes as an alternate to copper tubes for heat exchanger equipment. Constructed for liquid-to-liquid or steam-to-liquid applications, these coils are ideal for industrial processes and commercial water heating or cooling.


  • For Applications including comfort and process cooling , dehumidification, energy reclamation, chill water cooling, refrigerant cooling, glycol cooling and more
  • Multiple row depths and unlimited height or Length
  • All sizes, shapes, capacities, circuit patterns, fin/ tube configurations
  • Avaliable in 1- 6 row and from 6 to 21 fins per Inch
  • Match existing diamensions and performance for existing copper tube coils
  • Dublicate existing coils and custom design for new applications
  • For use with all types of refrigerants including  HFC's and non HFC's
  • Connection ends of copper for easy installing / brazing of copper to copper joint in the system.
Click here to view PDF

Table of comparison - Copper to Aluminum tubes

Table of comparison

Why all-aluminium heat exchangers ?


Even if this parameter is not the key feature, you will manufacture a more cost-effective system when you use aluminium.


If light weight and high performance are your ambitions, then selecting aluminium for your HVACR application will provide you with equipment lighter than devices using copper tubes – and you will always benefit from the space saved.

Weight saving with aluminium tube for an equivalent burst pressure: 36%


Why is corrosion an issue with Copper-Al heat exchangers ? Why is an all-aluminium design better

The corrosion rate of aluminium is very low when exposed to most environmental conditions, because aluminium is protected by a stable oxide layer. When corrosion does occur, it is typically due to poor design against corrosion. In a multi-material/alloy system where the materials are in direct contact, such as a heat exchanger or liquid lines, corrosion will take place on the most sacrificial part - the less noble part. Hence, it becomes essential to consider that the galvanic series become important. It is no surprise to see corrosion developing in a copper tube-aluminium fin heat exchanger, due to high electric potential difference. Aluminium as a stand-alone tube, when selecting the proper alloy, is resistant to even the aggressive environment, like sea water conditions.

Unlike conventional HVACR coils, all-aluminium heat exchangers are made entirely of aluminium. This “one-metal” concept eliminates galvanic currents that are generated when different metals touch in conventional coils. Many comparative tests, including the salt mist and ammonium sulphate test, provide proof of the increased corrosion resistance of all- aluminium heat exchangers.

Conclusion: Well-designed all-aluminium heat exchangers offer three-and-a-half times higher corrosion resistance than copper/ aluminium coils.

Heat transfer

Heat transfer was made for aluminium - and vice versa.

Using a drop-in aluminium tube in a mechanically expanded tube and fin heat exchanger will enable performance that is fully comparable with a traditional copper tube/aluminium fin heat exchanger.


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