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The producer of a starch base for mayonnaise needed a 3A approved product for cooking starch slurries used in-line. They were currently using a non-sanitary competitive direct steam injection heater to heat the starch slurry used in processing various starch based products. It was difficult to control temperatures and had to be taken out of line to adequately be cleaned.
SOLUTION
The solution was to install a 3A Sanitary Hydroheater®. It has no moving parts in the product contact area, is self draining and sealed for external washdown. It provides precise temperature control to ±1°F [0.5°C], produces instant heating of the product, and is 100% thermal efficient. The Hydroheater injects a precise amount of steam through the nozzle at a constant velocity, which results in a more homogeneous blending of the starch base, while also eliminating the risk for plugging and fouling. The instant heat transfer causes the steam to disperse into the product quickly, eliminating hammer and vibration associated with other similar type devices.
The Hydroheater in this application resulted in reduced maintenance, cut CIP cleaning time by a third, and produced a better cook out of the starch; this contributed to better cost control by utilizing less raw starch in the process. Also, the Hydroheater eliminated the need to shut down the production line to remove the heater for cleaning.
GOAL
• Acquire 3A heater for slurry heating
• Maintain accurate temperature control
• Reduce cleaning time
ACCOMPLISHMENTS
• Installed Sanitary (3A) Hydroheater
• Precise temperature control
• 100% thermal efficiency
• Cut cleaning time by 1/3
• Increased cost control with less starch usage
• Eliminated need to remove heater for maintenance
Are you curious about our patented direct steam injection technology? Click here to learn more.
Are you wondering what applications are ideal for direct steam injection? See the Where It Works section for the a list of industries.
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This tomato sauce producer was using a competitor’s 3-way steam valve heater with poor results. The unit had difficulty maintaining target temperatures, caused a loss of product due to burn-on, and consistently had issues with severe hammer and vibration. These issues caused concern over the piping’s integrity and added extra maintenance time and costs.
SOLUTION
A Solaris® Hydroheater, designed for highly viscous fluids was installed and successfully replaced our competitor’s 3-way valve heater. The straight-through flow design of the process steam heater minimizes flow disturbances and enables instantaneous condensation of steam without vibration or noise.
GOAL
• Eliminate safety concerns
• Reduce maintenance
• Maintain target temperature
• Improve product quality
ACCOMPLISHMENTS
• Installed Solaris Hydroheater
• Precise temperature control
• Eliminated safety concerns
• Minimized flow disturbances
• Enhanced product quality
Are you curious about our patented direct steam injection technology? Click here to learn more.
Are you wondering what applications are ideal for direct steam injection? See the Where It Works section for the a list of industries.
Do you want to learn more about our products? Click here for more information.
Flow Rate: Inlet Temperature: Outlet Temperature: Water Pressure: Steam Pressure: |
A certain poultry slaughter plant needed supplemental heating to their current Ludel heater during high demand production requirements in the sanitation and cleaning process. They needed: instantaneous hot water at up to 400 gpm [109 m³/hr], improved production with reduced cycle times and better temperature control.
SOLUTION
Hydro-Thermal® installed EZ Heater® model H2040 with a Medium (M) diffuser to meet the side-arm system requirements. The end user has realized the inherent advantages of the new unit’s design through instantaneous hot water, improved production with reduced cycle time, and eliminating scaling and fouling.
GOAL
• Supplemental heating during high demand
• Instantaneous hot water
• Reduced cycle times
• Accurate temperature control
ACCOMPLISHMENTS
• Instantaneous hot water
• Reduced cycle time
• Eliminated scaling & fouling
Are you curious about our patented direct steam injection technology? Click here to learn more.
Are you wondering what applications are ideal for direct steam injection? See the Where It Works section for the a list of industries.
Do you want to learn more about our products? Click here for more information.
Flow Rate: Inlet Temperature: Outlet Temperature: Water Pressure: Steam Pressure: |
A Midwest beef processing plant needed to maintain accurate temperature control and product quality for tripe washing in batch tanks. They were utilizing a direct fire heater to take the central hot water loop up to 155°F [68°C]. They then needed to augment that to 200°F [93°C] for proper tripe washing at fluctuating flow rates from 0 to 30gpm [0-7 m³/hr] running for 5 minutes and then off for 5 minutes. A competitive direct steam injection heater was doing this augmenting, but they were struggling to keep temperature due to scaling and performance issues, which is critical to the product quality and overall batch process.
SOLUTION
The end user replaced the competitor DSI heater with a H2010 EZ Heater® Skid system to assure accurate temperature control throughout the process. They now sustain precise temperature control, ensures product quality and eliminate excessive maintenance.
GOAL
• Maintain accurate temperature control
• Improve product quality
• Eliminate scaling
• Decrease batch time
ACCOMPLISHMENTS
• Eliminated over 1 hr/day in maintenance
• Precise temperature control
• Total uptime with no product loss
Are you curious about our patented direct steam injection technology? Click here to learn more.
Are you wondering what applications are ideal for direct steam injection? See the Where It Works section for the a list of industries.
Do you want to learn more about our products? Click here for more information.
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A pet food processor division of a conglomerate manufacturer featuring 50 leadership brands wanted to improve their process at the spray bar of the extruder and needed to maintain the proper viscosity of the meat slurry. Another main objective was to implement sustainability initiatives per their corporate plan.
At this location, an inefficient sparging system was in use that had trouble holding the proper water temperature. In addition, this system took up a lot of space and wasted energy. This company also needed better temperature control at the extruder for a more consistent product viscosity.
Learn More About Replacing a Steam Sparger
SOLUTION
A 1.0” EZ Heater® Skid System was installed to produce 195°F water at the spray bars of the extruder. The EZ Heater holds water temperature to within ±1°F assuring consistent and proper product quality.
The viscosity of the meat slurry in the extruder produces proper kibbles with moisture levels within process parameters and the EZ Heater saves space. The sparge system took up 4 times as much floor space as the EZ Skid™ and needed more clearance for maintenance work.
The company is pleased with the results as they positively affect their sustainability efforts. The energy required at the boiler for steam is 7% less than with the old system and the company is saving over $10,000/yr in energy costs. Also, maintenance at the sparge tank is no longer an issue and the peripheral equipment needs less attention because it is no longer damaged due to steam vibration.
Explore Our Industrial Steam Heaters
GOAL
• Maintain proper viscosity of meat slurry
• Implement sustainability initiatives
• Accurate temperature control
• Reduce footprint
• Decrease energy costs
ACCOMPLISHMENTS
• Improved product quality with consistent, uniform cook
• Precise temperature control
• Saving over $10,000/yr in energy costs
• Successfully implemented sustainability initiatives
• Reduced maintenance
Discover the Benefits of Direct Steam Injectin
Are you interested in learning more about how Hydro-Thermal can help you? Contact us today!
Hydro-Thermal is the global leader in the development and manufacturing of Hydroheaters. Through our vast global channel partners, we support hydro heating in six continents and all industrialized areas. We create heating systems for a variety of industries including: pulp, paper, chemical, ethanol, food & beverage, metal, & more!
Hydro-Thermal Corporation