A carpet manufacturing facility wanted to replace the current heat exchanger with a better water heating solution for their wash box station. They were looking for: energy efficiency, better temperature control, and better turndown control and capabilities.
Flow Rate: 200 GPM [55 m³/hr]
Inlet Temperature: 50˚F [10˚C]
Discharge Temperature: 110˚F [43˚C]
Water Supply Pressure: 85 psig [5.9 barg]
Steam Supply Pressure: 100 psig [6.9 barg]
SOLUTION
Hydro-Thermal’s EZ Heater® model H2030 with a Large (L) diffuser was installed to successfully adhere to each of the specifications desired. The customer has realized the inherent advantages of its design with:
• Easy installation and replacement of technologies • 28% more efficient than the heat exchanger • Instantaneous hot water on demand at exact temperature • Excellent turndown control and capabilities • Patented self-cleaning design to prevent scaling and fouling
GOAL
• Increase efficiency • Precise temperature control • Improve turndown control and capabilities
ACCOMPLISHMENTS
• 28% more efficient • Instantaneous exact temperature control • Lower maintenance • Excellent turndown
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.
This end-user saw an opportunity to use a waste whey product to initiate a waste-to-energy project according to their sustainability plan. They are the world’s second largest food producer selling into 170 countries and can trace its roots back to the 1700’s. They produce some of the world’s most recognizable and trusted food brands, and this particular plant produces cream cheese. The project included an anaerobic digester wastewater using whey waste from cheese production.
Our customer wanted to reduce their carbon footprint by focusing on six big impact areas of their business. One of those areas is waste. The company produces a cheese product in this plant, where waste whey is at a high volume and posed a disposal challenge. They chose this project to showcase a waste-to-energy initiative using bio-methane from waste treatment systems to produce energy for the plant.
Flow Rate: 200 GPM [45 m³/hr]
Inlet Temperature: 75°F [24°C]
Discharge Temperature: 95°F [35°C]
Steam Supply Pressure: 75 PSIG [5 barg]
SOLUTION
The solution was to use a K400 series Hydroheater® to heat the whey sludge to exact temperatures in an anaerobic digestion system. The Hydroheater heats to exact temperatures (±1°F) so the methane formingbacteria (archaea), effectively reproduces in the process to convert the sludge solids to biogas.
The plant now produces bio-methane from their on-site waste treatment. This process replaces 30-35% of the plant’s annual natural gas needs. Put in practical terms, the anaerobic digester creates enough biogas to heat 1,000 homes.
