Industrial Food Drying Ovens

Industrial Food Drying Ovens - Gas Catalytic Infrared v. Convection Technology

Industrial Food Drying Ovens - Case Study | Energy Efficient

“Heraeus Vulcan Gas Catalytic Infrared technology can safely be used on a wide range of foods and ingredients including grains, pulses and vegetables. Due to the nature of gas catalytic  reaction, there are no noxious gases produced to taint the food as only water and carbon dioxide is produced. Operators also report that yields and the quality of the dried foods are improved due to the highly consistent application of heat and the level of control available.”

Heraeus Vulcan

https://catalyticovens.com/heraeus-assists-metsa-improve-output-quality-reduce-operating-costs

Industrial Food Drying Ovens - Gas Catalytic Infrared is the Way Forward

Industrial Food Drying Ovens - Case Study. If a new or replacement industrial food drying ovens are being considered, then a close look at the available technologies is advised. The two most popular available are Gas Catalytic Infrared ovens and conventional convection ovens. There are significant differences that relate to speed, suitability and cost. One of the key advantages of Gas Catalytic Infrared energy is that when applied to organic substances such as water , it is readily absorbed. This means that it is the water that is heated up and thus evaporates very quickly. This is achieved with very low levels of air movement across the food being dried. The added advantage is that the greater the moisture content, the greater the proportion of infrared that is absorbed. This means that the whole drying process can much quicker.

The best method of applying the infrared heat is to pass the food to be dried on a flat bed conveyor system with some form of tumbling or vibrating bed to rotate the food , with the gas catalytic infrared panels placed in a shallow inverted 'V', above the conveyor. The length of the oven is determined by the required conveyor line speed, which in turn is determined by the required production output.

Added Control with a Gas Catalytic Infrared Oven

Because catalytic heaters can be arranged into zones, that allow precision control using a PLC system, one can have infinite control over the heat output of each zone, from 20% to full output. Heat profile recipes can be created and stored within the PLC control memory. In practice, this means that different recipes can be called up, to suit either different food substances to be dried, or, similar foods that have different moisture content from batch to batch.

What About Operating Costs?

In general Gas Catalytic Infrared, because it is much more efficient at converting the available energy in the gas to usable heat energy, is much less expensive to operate. Achieving the desired moisture content can take up to 80% less time than in a convection oven. Given that infrared ovens are inherently more efficient, then considerable savings can be expected. If the oven is a replacement for an electric oven then given the fact that Electrical Energy is around  four times as expensive as gas, then the savings become even more impressive.

Industrial Food Drying Ovens - Case Study

Types of Food That Can Be Dried With a Gas Catalytic Industrial Food Drying Oven

Heraeus Vulcan's gas catalytic infrared technology can safely be used on a wide range of foods and ingredients including grains, pulses and vegetables. Due to the nature of gas catalytic  reaction, there are no noxious gases produced to taint the food as only water and carbon dioxide is produced. Operators also report that yields and the quality of the dried foods are improved due to the highly consistent application of heat and the level of control available.

Finally, What about Bugs?

As insects, larvae and eggs have a high water content, they are heated up and killed off very quickly once they reach 60°C. This happens very quickly in the drying process, and means that pesticide use can be reduced or eliminated.

Energy Efficient Powder Coating System - Case Study

Energy Efficient Powder Coating Oven

Energy Efficient Powder Coating System - Case Study

Energy Efficient Powder Coating System - Case Study

“It used to take 70 minutes to cure our parts with the old convection oven. With the new Heraeus Vulcan oven, it now takes only 12 minutes! We are very satisfied with its performance!"

Mr Weikert - Company Owner

https://catalyticovens.com/heraeus-assists-metsa-improve-output-quality-reduce-operating-costs

Large Parts Curing in Record Time in Energy Efficient Powder Coating System

Working with our distributor in the Czech Republic, Surfin s.r.o, Heraeus Vulcan designed a new energy efficient powder coating system for Dikrt spol. s r.o. . The system is designed to cure powder on large agricultural parts, and the performance of the oven has exceeded expectation. Mr Weikert, the company's owner stated: "It used to take 70 minutes to cure our parts with the old convection oven. With the new Vulcan oven, it now takes only 12 minutes! We are very satisfied with its performance!"

How Did We Do It?

Working with our distributor in the Czech Republic, Jaroslav Blazek of Surfin s.r.o., the customer was able to see an existing Heraeus Vulcan system at another location and carry out part testing. Heraeus Vulcan then designed the powder coating oven to meet the customer's requirements using SolidWorks. Heraeus Vulcan then provided Surfin s.r.o with a package that included the sheet metal design, the Heraeus Vulcan infrared heaters and the controls. To see a video on how Heraeus Vulcan designs and builds ovens, please follow the link. The system was then easily constructed at the Surfin factory, with the sheet metal parts being produced locally from the SolidWorks files. The new energy efficient powder coating system was then installed and commissioned at the customer's site within a few days.

Advantages of a Energy Efficient Powder Coating System from Heraeus Vulcan

All Heraeus Vulcan energy efficient powder coating systems operate using the principles of gas catalytic infrared heating. This type of system has an energy to effective heat conversion ratio of 85%, compared to traditional convection oven which is only 5% - 7% efficient. In practical operation this results in curing  taking a third less time in a gas catalytic infrared oven than a gas fired convection oven. This translates into significantly reduced energy bills. The flameless nature of our systems means that there is no noxious emissions such as Nitric Oxide or Nitrogen Dioxide, so Heraeus Vulcan ovens are environmentally friendly. 

LPG Cylinder Painting With Gas Catalytic Infrared

LPG Cylinder Painting With Gas Catalytic Infrared

lpg cylinder powder coating oven case study
https://catalyticovens.com/heraeus-assists-metsa-improve-output-quality-reduce-operating-costs

"We now have a state of the art system which has delivered all the required improvements. Initial indications are that the system will pay for itself within the required payback period. I have been impressed with Heraeus Vulcan, Junair Spraybooths Ltd., and Gema's powder coating plant"

Simon Eldridge, Cylinder Supply Chain Manager at Flogas Britain

LPG Cylinder Painting System - Flogas Britain Ltd.

LPG cylinder powder coating oven case study. More companies involved in LPG cylinder painting and gas tank refurbishment are beginning to realize significant savings in time, energy and costs when moving to gas catalytic infrared systems. Heraeus Vulcan have recently completed a system for Flogas Britain Ltd., drawing on our experience with:

  • Aygaz in Turkey
  • Luxfer Gas Cylinders in the USA
  • Granby in Canada

New Gas Catalytic Infrared Line at Flogas Britain Ltd. 


Flogas Britain Ltd. approached Junair (Spraybooths) Ltd. to advise on how they could improve their current set up, which was old and effectively at the end of its useful life. The key improvements that the client was looking for included:

  • Moving from liquid to powder
  • More effective use of available space
  • Reduced operating costs
  • Improved quality
  • Added capacity

What We Did

Working with systems integrator Junair (Spraybooths) Ltd., we designed a Gas Catalytic Infrared oven, similar to designs we have used in the past for LPG gas cylinder painting. This was integrated into a system consisting of a Zinc degassing oven and  Gema automated spray booth. The infrared oven was designed by our engineers in the USA, and we provided Junair Spraybooths Ltd., with a complete package consisting of DXF files for the sheet metal structure of the oven, infrared heater panels and all the gas controls for each of the 6 zones within the oven.

The Flogas UK LPG Cylinder Painting Line Leaving Junair (Spraybooths) Ltd


Junair (Spraybooths) Ltd., built the oven in their facility. Within a matter of weeks, the oven was then ready to be shipped to site for installation. Once running, the PLC control system of the  infrared oven was setup with a number of heat profiles or recipes, to suit the different sizes of cylinder being processed, and stored in the memory for instant recall when needed.

Wheel Refurbishment Case Study

New Wheel Refurbishment Powder Coating Oven Delivers!

wheel refurbishment powder coating oven case study

“The successful conversion has allowed Snider Fleet Solutions to stay ahead of growing demand. The line is currently operating around the clock and we have the capacity to exceed 10,000 wheels per month. The biggest advantage of the new system is our ability to continually move parts through our process. It works very well now.The benefits of using efficient Gas Catalytic IR ovens has saved us a ton of gas already! Our old convection oven was very inefficient.The gas savings alone since the conversion have completely paid for the new ovens within 18 months of installation.”

Dave Double - Plant Manager Snider Fleet Solutions

https://catalyticovens.com/heraeus-assists-metsa-improve-output-quality-reduce-operating-costs

Wheel Refurbishment Powder Coating Oven

Snider Fleet Solutions in Greensboro, N.C. supplies tires, retreads and vehicle services to the transportation industry. The company operates a growing auto and truck wheel refurbishment service in Bluffton, Ind.

Until 3 years ago the company utilized a single convection oven that limited production to 3,000 wheels per month. They were also experiencing very high utility bills. Dave Double, Plant Manager at Snider Fleet Solutions needed a more flexible and cost effective solution. Dave carried out his research and concluded that Vulcan Catalytic Systems (now Heraeus Vulcan) was the best choice for revamping their systems.

So, the company installed a Vulcan (now Heraeus Vulcan) Gas Catalytic Infrared Powder Coating Oven to keep up with the growing demand for wheel refurbishment. They also adopted a new overhead track from Nikotrack, which incorporated staging areas to provide flexibility in the routing of parts through the system. This layout adopts a Lean Manufacturing approach, which ensures flexibility in batch sizes, to ensure that product is completed according the "pull" of the customer.

Overall, the new system has helped production to triple with the line currently running around the clock, powder coating 9,500 wheels per month, with the capacity to exceed 10,000 wheels per month. The full case study was published in Powder Coating Magazine.