Here's straight from each intercooler designer.
Superior to stock, everything about Banks Techni-Cooler Intercooler system is bigger. It includes mandrel-bent 3.5" high-flow boost tubes ... large, high-efficiency all-aluminum end tanks instead of the wimpy stock plastic ones that can rupture under high-boost conditions ... a wide-open inlet and outlet ... a 19% thicker core area with a 21% improvement in volume ... and a colossal super-flow High-Ram intake manifold.
Techni-Cooler dramatically increases the cooling capacity by balancing the richer fuel mixture with greater airflow and cooler, denser air. Denser air has more oxygen, which improves combustion as well as engine efficiency. Result: higher continuous power and more power at any exhaust gas temp (EGT), better fuel economy and lower EGTs. That's a truckload of benefits! Banks Techni-Cooler delivers the maximum reduction in boost air temperature with a minimal loss of boost pressure. It doesn't get any cooler than Techni-Cooler! Mounting hardware included.
This intercooler system reduces charge air temperature entering the engine, increasing the air density for increased power and torque, while reducing the overall thermal load on the engine and cooling system as exhaust temperature is reduced as much as 150 degrees F. This results in less transfer of heat to the cooling system and assists in maintaining normal coolant temperature on long hard pulls towing high gross weight vehicles
In addition to power and performance, you can anticipate an increase in fuel economy as the cooler, denser air creates a lean air/fuel ratio and in conjunction with less heat loss to the cooling system, fuel mileage can increase from 4% to 7% depending on driving conditions, weight towed, etc
I'd have to talk to Dave about the intercooler from DI if thats which one your refering to. As for AFE intercooler thats new ? when did they start making one ? Also here's another set of intercooler that Ive discussed with Greg and Brian at DPP. They also carry upgraded condensors and radiators as well.
Here's BD's Intercooler
500 degrees Fahrenheit... That's enough heat to cook a five-pound chicken in 45 minutes. It's also the temperature of the air going into your stock intercooler. Compressed air is heated air and when you combine an aggressive fuel curve with elevated boost levels, that can lead to convection oven levels of inlet temperature. That's why BD developed the new Cool-It intercooler.
With a larger cooling surface area and a thicker core, the Cool-It increases cooling effectiveness to approximately 90%, compared to only 70% for the stock intercooler. That can mean a temperature reduction of up to 200 degrees Fahrenheit over the stock intercooler. At the same time, the larger inlet and discharge tubes can handle up to 90 psi of boost and over 1500 cfm, while holding pressure drop to less than 1 psi. We guarantee this is the highest quality, best performing air-air intercooler on the market. BD's extruded tube design out performs other inferior Bar & Plate and Tube & Fin designs. The intercooler end tanks are precision hand welded for increased strength and a beautiful finish. Increased air flow, reduced air intake temperature, lower EGT's and higher HP, that's what you can expect from BD's new Cool-It intercooler.