Steam boilers play a vital role in the food and beverage processing industry. From the production of food to the final packaging stage, steam boilers play a key role in helping all types of processing processes to run smoothly. In this article, we will explore the full range of steam boilers in food processing applications, for you to introduce its type, characteristics, and how to correctly select the type, to help practitioners better understand and use this important equipment.
Next, we will first understand the specific application scenarios of steam boilers in food processing, then introduce the different types of boilers suitable for the industry, elaborate on the key features that need to be focused on when selecting a boiler, and finally give a practical approach to selecting the right boiler in the food and beverage industry.
Ensuring Food Safety
Food safety is always the primary concern of food processing companies. To ensure that the food and beverages produced are safe for public consumption, food processing plants must thoroughly clean, sterilize, and disinfect all tools, utensils, and operating tables used in the production process.
Against the backdrop of the New Crown outbreak, the importance of food safety has become more pronounced, and food processors need to follow additional process specifications to safeguard the safety of factory workers as well as the quality of the products leaving the factory. This is similar to the requirements of hospital operating rooms, where surgical tools must be strictly sterilized before and after use, and the utensils and operating tables used in food processing must also be ensured to be free of any germs or bacterial residues before food processing operations can be carried out.
Steam is the Best Choice
Steam boilers produce steam, which is often the best and safest way to sterilize and disinfect utensils and work surfaces, meeting standards set by the USDA, FDA, and the Centers for Disease Control and Prevention. The high temperatures of steam effectively kill germs and bacteria, ensuring food safety.
The Threat of Microbial Contamination
In the area of food safety, in addition to the problem of surface contamination, there is also the potential risk of microbial contamination within or on the surface of the food itself, where these bacteria and microorganisms may cause foodborne illness. Microbial contamination can come from raw materials, the processing environment, and all aspects of the process, posing a serious threat to consumer health.
Steam Pasteurization
Steam pasteurization is an effective method of controlling microbial risks during food processing. This process is made easier through the use of high quality steam produced in industrial boilers. The high temperature steam effectively reduces the number of microorganisms in the food without compromising the quality and safety of the food.
Steam Cooking
Some food processors require a significant amount of cooking before the food can be sold to the general public. While there are many different ways to cook or pre-cook food, cooking with steam and hot water from a boiler is one of the best ways to ensure that the food is smooth, soft and easy for consumers to digest. Steam transmits heat evenly, so food is heated more uniformly and localized overcooking or undercooking is avoided.
Complex Processes
More complex processes, such as curing and drying certain food products, also require steam. Because food processing is often a large-scale production operation, large quantities of steam and hot water are often required at certain times to meet production demands. Steam helps to control humidity, temperature and other critical factors in these processes to ensure product quality and flavor.
The Role of Climate Control
The efficient operation of a food processing company is not only dependent on state-of-the-art machinery and equipment, but the hard work of employees is also critical. In a food processing plant, climate control plays a key role in improving productivity and ensuring employee safety. The right working environment improves employee motivation and productivity, and helps to ensure the stability of the food processing process.
The Dual Purpose of Steam Boiler Systems
In many cases, steam boiler systems used in all phases of food production can also provide heating for plant facilities. This system is utilized to meet the demand for steam for food processing, as well as the heating needs of the plant's interior, making efficient use of resources.
Types of Steam Boilers Suitable for Food Processing
Principle of Operation
Fire tube boilers work on the principle that hot gases pass through tubes surrounded by water, gradually heating the water to steam over time. In the process, the heat from the hot gases is transferred to the surrounding water, causing the water to heat up and eventually boil to produce steam.
Advantages & Suitability
The firetube boiler is ruggedly constructed and relatively easy to maintain. Because of these characteristics, it is ideal for food processing facilities that have a moderate demand for steam output. For smaller companies or those with relatively constant steam usage, firetube boilers can meet their production needs while providing advantages in terms of maintenance costs and ease of operation.
Mechanism Of Operation
Water tube boilers operate by circulating water through tubes that are heated by external combustion gases to rapidly produce high pressure steam. The combustion gases release heat on the outside of the tubes, which is efficiently transferred to the water inside the tubes, causing the water to rapidly heat up and convert into high-pressure steam.
For Large Capacity Facilities
Because of their ability to respond quickly and produce large quantities of high pressure steam, water tube boilers are particularly well suited for those large capacity food processing facilities. In large-scale food processing plants, where the scale of production is large and the demand for steam is high and requires a rapid supply, water tube boilers are well suited to meet these production needs and ensure that the production process is carried out efficiently.
Emission-Free Operation
Electric boilers do not involve a combustion process in their operation and therefore do not produce emissions. This feature makes the electric boiler run with minimal pollution to the environment, in line with the pursuit of environmental protection by modern enterprises.
Suitable For Small Businesses
Electric boilers are not only environmentally friendly, but also require relatively little maintenance, making them ideal for small food processing companies that focus on sustainable development. Small businesses are usually more cautious in equipment investment and operating costs, the low maintenance costs and environmental characteristics of electric boilers can save their operating costs, while meeting the production needs.
Biomass Boilers
Renewable Fuel Sources
Biomass boilers are fueled by renewable resources, such as wood pellets or agricultural waste. These renewable materials release energy during combustion to power the boiler, while reducing reliance on traditional fossil fuels.
Reducing Your Carbon Footprint
Biomass boilers are becoming an increasingly popular option for food processing companies that are committed to reducing their own carbon footprint. The use of a biomass boiler can significantly reduce a company's carbon footprint, which is environmentally friendly and helps them to achieve their sustainability goals.
High Thermal Efficiency
The Importance Of Efficiency
In the food processing industry, high thermal efficiency plays a crucial role in reducing fuel costs. An efficient boiler converts more fuel energy into useful heat, reducing wasted energy and resulting in significant savings in operating costs.
Types of High Efficiency Boilers
Boilers like condensing boilers and boilers equipped with economizers effectively capture excess heat, resulting in thermal efficiencies of 85% or more. Condensing boilers improve energy utilization by recovering latent heat from the steam, while energy savers further improve the overall thermal efficiency of the boiler by recovering heat from the exhaust gases emitted from the boiler.
Advanced Combustion Control
Automation Control
The advanced combustion control adopts automation control technology, such as the oxygen regulation system, which continuously and automatically adjusts the ratio of air to fuel to achieve the best combustion effect. During boiler operation, the air and fuel inputs are adjusted in real time according to the actual combustion conditions to ensure adequate fuel combustion.
Improved Efficiency and Reduced Emissions
This automated control not only maximizes fuel efficiency, but also significantly reduces exhaust emissions, meeting stringent environmental standards. By accurately controlling the combustion process, pollutants from incomplete combustion are reduced, while energy efficiency is improved, resulting in a win-win situation for both the economy and the environment.
Role of PLC
Programmable Logic Controllers (PLCs) enable automated control of boiler temperature, pressure and water level. Through a preset program, the PLC can automatically adjust the relevant parameters according to the actual operating conditions, ensuring that the boiler is always in a safe and stable operating state.
Real-Time Monitoring
The system equipped with human-machine interface (HMI) screen can provide real-time monitoring function, the operator can clearly understand the operating parameters and working status of the boiler through the screen, and have a comprehensive control over the performance of the boiler. In the event of an abnormality, it can be detected in a timely manner and appropriate measures can be taken to ensure the safe operation of the boiler.
Key Safety Features
The safety system of the boiler contains several key safety features, such as low water level cut-off device, safety valve and flame protection system. These safety devices are an important line of defense to ensure the safe operation of the boiler.
Ensuring Safety
In the event of an unsafe condition such as low water level, high pressure or abnormal flame during boiler operation, these safety devices can automatically activate to shut down the boiler immediately, preventing safety accidents and protecting plant facilities and employees' lives.
Durability and ease of maintenance
Corrosion-Resistant Materials
The use of corrosion-resistant materials, such as stainless steel, is critical in the construction of boilers. Corrosion-resistant materials are effective in resisting a variety of corrosive substances that may be present in food processing environments, prolonging the life of the boiler and reducing equipment replacement costs.
Modular Design
Boilers with a modular design are easier to inspect, clean and maintain. The modular structure makes each component relatively independent, easy to disassemble and install, and maintenance personnel can more quickly maintain specific components, reducing equipment downtime and improving production efficiency.
According to the production process
First of all, the saturated steam parameters of the boiler should be determined accurately based on the requirements of the food and beverage production process. Different production processes have different requirements for steam temperature, pressure and flow rate parameters, only to meet these parameters to ensure the smooth progress of the production process.
Advantages of Saturated Steam
Saturated steam has a significant advantage in the production process in that it maintains a constant temperature, which is critical for temperature control in food processing. Stable temperatures help ensure consistent product quality and avoid product quality problems caused by temperature fluctuations.
Overcoming Pressure Losses
Typically, boiler pressure needs to be higher than the saturated steam pressure required for production. This is to overcome the pressure loss that occurs when steam is transferred through a piping or tubing network. As steam flows through piping, it rubs against the inner walls of the piping, resulting in a gradual decrease in pressure.
Calculating the Proper Pressure
When calculating boiler pressure, the pressure required for actual production plus the pressure drop required to overcome all piping resistance, plus an additional 25% to 30% pressure margin is sufficient. This ensures that steam will be available for production under all operating conditions, while avoiding the safety risks and energy waste associated with excessive pressure.
List of Boiler Types
Boilers are categorized by fuel type as oil and gas boilers, coal-fired boilers, biomass boilers, and electric boilers. Different types of boilers have their own characteristics in terms of performance, cost and environmental protection.
Fuel Selection Considerations
The state has strict control measures on coal-fired boilers to reduce the pollution caused by coal burning to the environment. Gas-fired boilers, on the other hand, have the advantage of more precise temperature control. However, when choosing a gas-fired boiler, you need to consider whether it is convenient to install gas piping. If there are difficulties in installing gas piping, then consider using an oil-fired boiler or an electric boiler as an alternative.
Determine The Boiler Structure
Multi-Factor Consideration
In addition to the three basic factors of the boiler's power output, the parameters of the working medium and the applicable coal type, there are many other aspects to consider. For example, the external dimensions of the boiler, which is particularly important in the original boiler room for expansion; load fluctuations in the production process, which affects the stability of the boiler operation; water quality requirements, different water corrosion of the boiler to a different extent; air pollution, the need to select the boiler to meet environmental requirements; the degree of mechanization and automation, which is related to the production efficiency and labor costs; as well as the main and auxiliary engine selection to ensure that the matching and compatibility between the various components. matching and compatibility between components.
Boiler Room Expansion
When considering boiler room expansion, the size of the boiler must be fully considered. Boilers produced by different manufacturers may differ greatly in size, and users need to understand the manufacturer's product specifications in detail in order to make reasonable arrangements for boiler room planning and equipment installation.
Capacity and Model
Selecting Similar Boilers
When selecting a boiler, try to choose a boiler with the same capacity or the same combustion equipment. This can reduce a lot of unnecessary trouble during the operation and maintenance of the equipment, for example, operators can be more familiar with the operation process of the same type of equipment, and maintenance personnel are more likely to grasp the key points of equipment maintenance.
Limit Model Differences
If it is not possible to select all boilers of the same model, at most two different models can be selected to minimize equipment layout and management difficulties caused by too many equipment models. Too many models can increase the complexity of equipment management, raising maintenance costs and the probability of errors.
This paper reviewed the importance of steam boilers in the food and beverage processing industry, covering their applications in sterilization and disinfection, microbial risk reduction, cooking and curing and drying, and facility heating; described the characteristics and applicability of different types of boilers, such as fire-tube, water-tube, electric, and biomass boilers; and elaborated on the need to focus on high thermal efficiencies, advanced combustion control, when selecting a food processing boiler, PLC automation, safety systems, and key features such as durability and ease of maintenance when selecting a food processing boiler; finally, specific methods for determining boiler capacity, pressure, fuel, structure, and model selection are given.
It is hoped that when selecting a steam boiler, practitioners in the food and beverage processing industry will take into full consideration their specific needs and, with the information provided in this paper, make informed, rational decisions to ensure an efficient, safe, and sustainable production process.
The characteristics of the various types of boilers in the exposition is clear, or in the choice of boiler method of explanation is easy enough to understand, have their own views? Feel free to let me know and we'll refine it together.
