A long-time customer was looking for a solution to their struggles packaging tomato paste into aseptic containers. During the long 14-week season, the Solaris heating system ran well, optimizing performance to provide a quality product and a stable operation. The Solaris was customized to meet the unique demands of heating both hot- and cold-paste of 28-35% NTSS. This successful solution incorporated a custom Solaris heater built into a supply manifold and steam conditioning system for a 4 inch [DN100] aseptic paste line.
Fluid: Hot and Cold-Break Paste
Circulation Rate: 60-300 GPM [14-68 m³/hr] (turndown in configured system is 2:1)
Inlet Temperature: 180-195°F [82-91°C]
Discharge Temperature: 212-218°F [100-103°C]
Temperature Rise for a Single Heater: 17-38°F [9-21°C]
Steam Supply Pressure: 175-300 PSIG [12-21 barg]
SOLUTION
A season of trials resulted in a system package designed for either 4 or 6 inch [DN100 or DN150] aseptic paste lines. Solution includes custom Solaris heaters in either single or dual pass with a frame constructed of welded square tubing with feet to anchor into concrete plus schedule 40 piping and flanged connections at the inlet and outlet. The steam line includes a drip leg and steam trapping to ensure dry steam supply. Isolation and check valves prevent paste from backing up into the steam line. An additional steam conditioning system will be provided with a pressure control loop and culinary filter if necessary. In addition, the system is supplied with wiring to allow flexibility in control systems, unless existing temperature and pressure transmitters can be used.
GOAL
• Decrease vibration & hammering • Decrease burn-on to extend or eliminate cleaning cycles • Achieve more precise temperature control
ACCOMPLISHMENTS
• Eliminated burn-on (up to 4 weeks with no deposits or burn-on) • Eliminated steam hammer in heating system and downstream piping • Minimized high frequency vibration • Consistent temperature control during feed-forward production • Flow turndown exceeded 2:1 without a change in stable operation • Pressure swings up to 100 psi during divert mode to feed-forward transition had no effect on heater stability
A major US Brewer needed an efficient and reliable method to precisely heat circulated water/solutions for a CIP application of beer filler lines. The application presented a variable heating load of 0-35° temperature rise requirement. To simplify system design and accomplish the degree of control necessary under the variable conditions, the decision was made to use direct steam heaters. The original installation utilized a competitive heater which proved incapable of operating smoothly over the entire range of temperature requirements. Excessive hammering during operation required frequent disassembly to repair internal components.
Fluid: Recirculated Water
Flow Rate: 175 GPM [40 m³/hr]
Inlet Temperature: Variable; 60-185°F [16-85°C]
Discharge Temperature: 185°F [85°C]
Temperature Rise per Pass: 0-35°
Steam Supply Pressure: 70 PSIG [7 barg]
SOLUTION
The K411AS Hydroheater® was evaluated by the engineering team as a replacement heater for the CIP application. Final decision to purchase the Hydroheater was based on simple geometry and the unique feature of internal steam modulation. This enables the Hydroheater to operate smoothly over the entire range of steam flow (temperature) requirements without hammer or instability. To simplify installation, the Hydroheater was supplied as a complete package with temperature controller.
The Hydroheater was installed in early 1989 and has met performance expectations by providing smooth, hammer-free operation with precise control of loop temperature. The successful performance of the Hydroheater has resulted in the installation of Hydroheaters on two additional CIP systems.
GOAL
• Precise temperature control with varying conditions • Simplify CIP design • Smooth operation
ACCOMPLISHMENTS
• Installed K411AS Hydroheater • Smooth operation over varying conditions • Simplified design with temperature controller • Eliminated hammering • Installed Hydroheater on two additional CIP lines
Ice cream producer Blue Bell Creameries in Broken Arrow, Oklahoma was looking to optimize their clean in place (CIP) and clean out of place (COP) operations. They were using a hot water tank with a steam heat tube bundle. This system had a fixed volume of water capacity with a long recovery time. The system’s limitations were especially frustrating during transition periods of full production to cleaning.
“The standard for reliability is how long can equipment be used with scheduled maintenance with no unplanned downtime. This equipment will operate for months and months with no downtime with a variety of skill level operators.”– Mike Tate, Maintenance Manager at Blue Bell Creameries
SOLUTION
After researching alternative options, Blue Bell Creameries selected a Hydro-Thermal 2-inch EZ Heater skid with a 3-inch steam line. The system has been in production since August 2015, and it can fill multiple tanks quickly at proper temperatures.
Operators can also quickly and easily adjust temperatures, which fixed problems during transition periods that occurred with their previous equipment.
• Able to fill multiple tanks quickly at proper temperatures (reliable hot water on demand) • Quick, easy temperature adjustments • Efficient transition periods between full production and cleaning
This large Midwest beef processing plant needed to maintain precise temperature control at a point-of-use hot water station for beef feet cleaning (a CCP – critical control point). As the final product is for human consumption, beef feet cleaning must reach and maintain proper temperature per USDA requirements. If 160°F [71°C] is not met, this will result in a loss of product, time, and energy.
Flow Rate: 0-75 GPM [0-17 m³/hr]
Inlet Temperature: 140°F [60°C]
Discharge Temperature: 160°F [71°C]
Water Pressure: 50 PSIG [3.4 barg]
Steam Supply Pressure: 120 PSIG [8.3 barg]
SOLUTION
Hydro-Thermal® replaced (3) Emech mixing valves with an H2015 EZ Skid™ system dedicated to the beef feet point-of-use station. By adding this system, the plant was able to lower its central hot water system set-point from 160°F [71°C] to 140°F [60°C].
By replacing their valves with the EZ Skid™, the processing plant saved on energy, time, maintenance and ensured product quality with an estimated $42,000/yr in energy savings.
GOAL
• Maintain precise temperature control • Decrease batch time • Enhance product quality
ACCOMPLISHMENTS
• Lowered set-point temperature • 6 month ROI • Simplified the point-of-use process • Reduced maintenance to a once a year check
Are you wondering what applications are ideal for direct steam injection? Visit our industries page to learn more about industries and applications.
A large pork processing plant needed to supply 180°F water to critical applications throughout the plant with fluctuating flow rates. The main challenge was to find the true flow rates in order to size the system properly for different variables. The viscera process (removal of internals and wash-out of cavity) stays at a constant 75 gpm but has a variety of hoses, saws and sanitizers which makes the flow range from 75 gpm up to 200 gpm at different times during the day. The primary concern is always maintaining 180°F+ at the point of use to avoid shutdowns and downtime, and secondly, reducing energy and maintenance costs.
Flow Rate: 75-200 GPM
Inlet Temperature: 130°F from Rendering
Discharge Temperature: 200°F
Water Pressure: 60-70 PSIG
Steam Supply Pressure: 100 PSIG
SOLUTION
Hydro-Thermal® designed and installed a 3” EZ Heater Skid system to replace a shell and tube heat exchanger and utilized the tank as a buffer to smooth out the fast flow fluctuations (turndown). The EZ Heater Skid system pulls hot water from rendering operations at approximately 130°F and heats it to a consistent 190°F on the floor (under 180°F causes plant shutdowns that cost $300/min of downtime, over 200°F burns on tallow to pans, knives and conveyors).
Exact details of pipe sizings, applications and flow rates enables the system to keep a constant temperature on the floor and meet the stringent demands of the USDA.
GOAL
• Maintain precise temperature control for fluctuating flow rates • Avoid unscheduled shutdowns and downtime • Reduce energy costs • Reduce maintenance time and costs
ACCOMPLISHMENTS
• Consistant temperature control at all flow rates • Constant up-time due to reliability • Dramatic maintenance savings • 15-20% in energy savings
Are you wondering what applications are ideal for direct steam injection? Visit our industries page to learn more about industries and applications.
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.
Flow Rate: 400 GPM [109 m³/hr]
Inlet Temperature: 45°F [7°C]
Outlet Temperature: 150-200°F [66-93°C]
Water Pressure: 100 PSIG [6.9 barg]
Steam Pressure: 100 PSIG [6.9 barg]
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 wondering what applications are ideal for direct steam injection? Visit our industries page to learn more about industries and applications.
Factory with pharmaceutical equipment mixing tank on production line in pharmacy industry manufacture factory
A seafood company that has been a major supplier of clams for over 25 years needed a heating solution with the flexibility to handle several different recipes while eliminating product waste and preventing tank burn-on. The end user was adding several recipes to their product line and needed a solution that could handle different operating conditions for food starch concentrations ranging from 0-22% (potato, corn, clear jell, and more). They have been using a Hydro-Thermal competitor’s direct steam injection heater but found it difficult to clean and maintain. This disrupted their production cycle and increased batch time.
Fluid: Up to 22% Starch Slurry
Flow Rate: 30 GPM [6.8 m³/hr]
Inlet Temperature: 50°F [10°C]
Discharge Temperature: 195°F [91°C]
Steam Supply Pressure: 100 PSIG [6.9 barg]
SOLUTION
Hydro-Thermal installed an A307 Sanitary Hydroheater® turn-key skid system to address plant expansion and new product lines. A culinary steam filter was also provided to ensure product quality and consumer safety by USDA regulations. The Sanitary Hydroheater is 3A certified and uses patented technology that produces sonic velocity steam through the nozzle, preventing product burn on and fouling of the heater.
The sea food producer is now able to process several different recipes using the same equipment and has reduced waste while improving quality of the end product.
Update: Plans to install additional Hydroheaters throughout their plant for continuous improvement and sustainability efforts.
GOAL
• Eliminate product waste • Prevent tank burn-on • Ability to heat different operating conditions • Decrease batch time
ACCOMPLISHMENTS
• Improved product quality and reduced waste • Reduced cycle time • Reduced maintenance costs and time
Are you wondering what applications are ideal for direct steam injection? Visit our industries page to learn more about industries and applications.
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.
Fluid: Tomato Sauce
Flow Rate: 25-75 GPM [6-17 m³/hr]
Inlet Temperature: 45°F [7°C]
Discharge Temperature: 195°F [91°C]
Steam Supply Pressure: 120-130 PSIG [8-9 barg]
Viscosity: 75,000 cP
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.
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.
Flow Rate: 0-30 GPM [0-7 m³/hr]
Inlet Temperature: 155°F [68°C]
Outlet Temperature: 200°F [93°C]
Water Pressure: 55 PSIG [3.8 barg]
Steam Pressure: 75 PSIG [5.2 barg]
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 wondering what applications are ideal for direct steam injection? Visit our industries page to learn more about industries and applications.
An original equipment manufacturer (OEM) wanted to use a direct steam injection heater in a large milk and ice cream aseptic system for ultra high temperature (UHT) pasteurization in a midsized Northeast dairy. After reviewing the results of other Hydro-Thermal dairy pasteurization installs, the company was eager to incorporate a Hydroheater into this system. The pasteurization system that the OEM was working with was having difficulty holding precise temperature and was experiencing fouling problems resulting in several daily cleanings.
Flow Rate: 125 GPM [28 m³/hr]
Inlet Temperature: 175°F [79°C]
Discharge Temperature: 290°F [143°C]
Steam Supply Pressure: 100 PSIG [7 barg]
SOLUTION
They purchased an A210 Sanitary Hydroheater because it is 3A certified and is able to process food with low acidity.
The OEM successfully incorporated the A210 Hydroheater into the larger aseptic system. They are happy with the Hydroheater’s use of sonic velocity resulting in a complete homogeneous blend of condensate with the product that reaches precise temperature in milliseconds. The hold tube is cleaner and easier to maintain compared to other direct steam injection heaters. In fact, the elimination of fouling resulted is lower maintenance costs. Finally, the flavor of the milk and ice cream mix has improved which the OEM has not experienced with any other steam injector or infuser.
Improve Your UHT Pasteurization Process
Are you looking to improve your ultra-high temperature pasteurization process? Our line of Jetcookers & 3A certified Sanitary Hydroheaters can help you with precision temperature controls & eliminate issues. Request a quote today to improve your UHT system.
GOAL OF USING DIRECT STEAM INJECTION PASTEURIZATION
• Precise temperature control • Eliminate fouling issues • Decrease daily cleanings
ACCOMPLISHMENTS
• Installed A210 Sanitary (3A) Hydroheater • Precise temperature control within milliseconds • Eliminated fouling issues • Lower maintenance costs • Improved product quality
Are you wondering what applications are ideal for direct steam injection? Visit our industries page to learn more about industries and applications.
