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Starch process drawing

Starch is a diverse industry that encompasses multiple products including sweeteners, paper products, foods such as soups, mayonnaise, and beverages. Each of these producers have their own unique concerns. 

Achieving the maximum conversion of starch to sugars is the key goal in both the ethanol and sweetener industries. Once the sugars are created, the goals in these industries change but the process in both to create those sugars is very similar. The need to be able to produce and maintain a very accurate uniform temperature in the mash flow and being able to create an adjustable shear are the two key features provided by the Hydroheater/Jetcooker. Being able to adjust the ΔP is achieved by Hydro-Thermal’s adjustable combing tube. This feature provides the ability to create the optimal amount of shear to optimize yield, produce a very high level of product quality in the case of sweetener plants, reduce enzyme use, and reduce overall energy use. Hydro-Thermal’s patented heating solution addresses these issues and comes with a team of experts ready to help you achieve your processing goals.

Hydro-Thermal’s patented heating system works by mixing steam and process liquids completely while delivering consistent temperature and instantaneous heating. For more information on our advanced direct steam injection technology, click here.

Heating products utilizing direct steam injection

The type of heater you need is dependent on how it will be used. No matter what your application, Hydro-Thermal has the solution for every application involving the starch industry.

All of our heaters share unique benefits, including internal modulation, self cleaning ability and rugged design and construction.

Here is what makes each solution unique:

Industrial Hydroheater (Also known as the Jetcooker™)

  • Volume capability: flow rates up to 6,700 gpm [1,522 m³/hr]
  • Precise temperature control ±1°F [.50°C]
  • Available in a variety of alloy materials including: Stainless Steel (316, 316L, 317L, AL6XN, 254SMO & 2205), Hastelloy & Titanium.
  • Adjustable pressure drop to control the shear (high or low)
  • High steam capacity
  • High solids capability
  • Hydroheater has a liquid turndown of 2:1 for starch conversion, and up to 3:1 for water-like fluids. If a greater turn-down is required consult Hydro-Thermal Engineering.
  • Available in sizes from 1/8” to 12”
  • Rating: 1/8” to 2-1/2” NPT (300 psig at 450 F), 2” to 12” flanged (150# 195 psig at 400 F, 300# 300 psig at 450 F, PN16 16 barg at 221 C, PN40 20.7 barg at 232 C)
  • Right angle design
  • All Industrial Hydroheaters include a combining tube. An extended combining tube may be recommended for a large ΔT (high temperature rise). Please contact Hydro-Thermal for more details.
  • For more information on the Hydroheater, click here.

Sanitary Hydroheater

  • Applications: Food and beverage processing, water heating if 3A certification is required
  • Volume capability: flow rates up to 180 gpm [41 m³/hr]
  • Precise temperature control ±1°F [.50°C]
  • Available in sizes from 1/2" to 2-1/2"
  • Liquid Turndown: 2:1
  • Liquid Viscosity: Up to 20,000 cP
  • Rating: 150 psig @ 400°F
  • Back Pressure: Up to 60% steam
  • There are 3A certified polished versions or unpolished versions available.
  • Tri-clamp connections, but I-Line connections are available upon request.
  • Self-draining from multiple orientations and designed for easy CIP.
  • Right Angle Design
  • For more information on the Sanitary Hydroheater, click here.

EZ Heater

  • Volume capability: 2 up to 1,350 gpm [.5 up to 306 m³/hr]
  • Precise temperature control
  • High temperature rise
  • High turndown capabilities for large flow fluctuations
  • Ability to set more than one temperature
  • Unlimited on-demand hot water at precise temperature
  • Easily plumbs into existing plant utilities
  • Pre-designed and partially stocked for short lead times
  • For more information on the EZ Heater, click here.



SilverLine™ Smart Cooking System

  • Sanitary 3A, CE certified and FDA compliant, stainless steel system for starches, slurries, and high solid products.
  • Volume capability: 5 up to 200 gpm [1.1 up to 45 m³/hr]
  • Uses: tomato paste, sauces, soup stocks, salsa, meat slurry, vegetable blanching, cheese production, dairy based drinks and sauces, beverages.
  • For more information on the SilverLine, click here.


Actuator Options Available

Hydro-Thermal's heaters utilize a Fisher reverse-acting diaphragm actuator (“fail close”). Generally coupled with a filter/regulator and a Fisher DVC 2000 or a DVC 6200 positioner that converts a 4-20 mA DC input signal to pneumatic output signal to the actuator. For high vibration applications remote mount positioners are available. Alternative positioners are available depending on unique processing conditions or upon request. Please contact Hydro-Thermal for more details.


Non-Obstructing Heater (NOH)

  • Volume capacity: 30 up to 6,900 gpm (6.8 up to 1,567.2 m3/hr)
  • Body and stem plugs in 316SS, and diffuser in 316L or 17-4PH (other materials available pending on request or per application)
  • Straight tube design allows unrestricted flow
  • Low pressure drop
  • Trim heating control for high turndown
  • Able to handle abrasive (sand or grit) and large particulate/fibrous materials
  • Available in sizes from 2” to 12”
  • Heater rating of 300 PSIG @ 450°F
  • Raised face flanges designed per ANSI B16.5 with lugged connections
  • For more information on the NOH, please click here.



Fluid Heating Systems

EZ Skid™: Complete skid systems utilizing the EZ Heater®. The EZ Skid is available in 5 standard sizes and is only used for hot water applications. For more information, click here.


ATTEC®: ATTEC or Advanced Fluid Heating Skids are completely customized solutions that are designed, built and installed to individual specs. Hydro-Thermal will provide necessary components including piping and control systems. These skids can be used for processing any type of slurry including starch cooking, food manufacturing, chemical processing and everything in between. For more information, click here.


Applications for Starch Production

Learn More...

For more information on our products, click here.
For more information on our patented direct steam injection technology, click here.
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