Why Maintain a Uniform Temperature within the Dryer

Quality of product being dried depends on the time and amount of heat they are exposed to; heating temperature plays a crucial role in the overall development of products within the oven, hence stable temperature is key to success here. Temperature uniformity doesn’t only mean maintaining the same temperature across but it means having the desired temperature across every section of the oven with the same consistency throughout its operational time.

How can we achieve this consistency? The answer is very simple just by reducing the temperature fluctuation but the implementation of the same is complex. One of the ways to reduce this fluctuation is reducing temperature losses by using proper insulation of the chamber using reliable material and methods. Continuously monitoring and controlling is key for the implementation of the dryer with uniform temperature.

Kerone’s dryer is built with superior quality materials with cautiously taking care of each and every required measure; secondly, all dryers are fitted with an intelligent feedback loop with various sensors fitted at different sections for monitoring these measured temperatures are fed to correction unit; this correction unit compares the deviation and accordingly decides to increase or decrease firing to maintain the ultimate temperature stable. Kerone implements even really complex control mechanisms as well based on the customer’s process and product requirements.

Uniformity with Temperature brings in various advantages:

Consistent Product Quality:

Maintaining minimum temperature deviation ensures every piece of the product is treated with the same temperature hence quality will be the same, also too much deflection in drying temperature sometimes results in compromised product quality. Heat sensitive materials might result in a lot of wastage.

No or less re-processing:

If we fail to maintain uniformity it might result that some materials are not processed as desired and this might require refeeding for processing. Many heat-sensitive materials will not allow this as well.

Fewer Losses and Wastage:

Materials treated in uniform temperature always attain better quality, however fluctuating temperature results in too hot and too cold-processed material when you try reprocessing them they over dry and loose its effectiveness, quality and result in unusable and results in the increase of waste.

How to maintain uniform temperature:

There are multiple ways to attain uniform temperature across oven, insulating is one of them:

Controlled Air Flow:

The volume and direction of airflow inside an oven influence the temperature consistency. A high volume of air is alluring, as the higher the volume, the better the warmth consistency. In a perfect world, airflow inside a stove arrives at all pieces of the oven similarly. This airflow can be either horizontal or vertical however should be steady to continue a steady temperature.

Insulated walls to minimize losses:

An oven’s insulation shifts in thickness as indicated by the oven’s temperature and consistency prerequisites. Additionally, utilizing extraordinary boards and unitized development decreases an oven’s through-metal warmth misfortune, adding to more prominent warmth consistency.

Air Distribution:

Appropriately positioned openings help keep up positive air pressure inside an oven, decreasing the danger of cool air leaking through the entryway seals. Before entering the work chamber, new, cool air should go through heating components and blend in with hotter, recycled air. This blending forestalls layers of various temperatures inside an oven.

Understanding Conveyor Belts and Conveying Techniques

You made great choice of processing equipment, all aspects were critically evaluated and you have pondered on every requirement, but it seems you have either missed or left it on technology partners to take call on conveying systems (material transportation) this might become your bottleneck in future. Hence it’s important to understand the different type of conveyor belts those will carry your material. Below we are try to introduce you with few of such belts:

Roller Bed Conveyor Belts

The surface of this type of conveyor belt is comprised of rollers that are chosen to match production requirements, such as the weight or required speed of the items that will move along the belt. Shorter conveyor belts that fall under this type can be made up of just two rollers. However, as the distance between the two ends of the belt increases, more will be required for the belt to work.

A roller bed arrangement is reasonable for when items are loaded onto the belt with gravity. This is because manual loading can cause mechanical shock and damage the rollers. Roller bed conveyor belts are also a good option for transporting items over long distances as they reduce friction, making it simpler for items to move along the belt.

Flat Belt Conveyors

The flat belt conveyor belt is one of the most pervasive conveyor frameworks being used today. Flat belts are useful for internal transport, for example shipping things inside an office. This kind of conveyor belt utilizes a progression of controlled pulleys to move a persistent flat belt, which can comprise both of common material or manufactured texture (ex. polyester, nylon). Things are set on the moving belt and conveyed from one end to the next.

Since its belts can be made of various types of materials, this kind of conveyor belt is unimaginably adaptable. Discretionary highlights incorporate focus drives and nose bars relying upon the prerequisites of a given application. Flat belt systems are often the conveyor of choice for industrial environments, wash down areas, and slow assembly lines. Fitted with the right belt, it can also convey small, soft, or irregularly shaped items without harming them.

Modular Belt Conveyors

While flat belt conveyors use a single, continuous loop of material, modular conveyor belt systems use a single loop made of countless interlocked pieces, usually made of hard plastic. These portions can be removed and replaced individually, in contrast to having to discard the entire belt. They’re also easier to wash, as well as more resistant to sharp and abrasive materials. This makes modular belt conveyors simpler to maintain and fix than their flat belt counterparts.

Modular belt conveyors are appropriate to applications that include going around corners. Indeed, they can travel straight, circumvent a corner, and slope and decrease utilizing a solitary belt and a similar engine all through. Actually, different kinds of conveyors can likewise achieve this accomplishment, yet just with much customization and extra expenses. Plastic modular belts additionally permit explicit conveyor plans without trading off belt following. A case of this is a belt with more noteworthy width than length, which offers the help required to deal with delicate plastic packs, cardboard boxes, and therapist wrapped goods.

Cleated Belt Conveyors

Cleated belt conveyors highlight vertical spikes or obstructions in their structures. These spikes can keep free materials secure during slopes and decays, to give reliable dividing among things, and that’s only the tip of the iceberg. Moreover, spikes come in various shapes, each with its own application.

Type of Cleated Belts:

  • Inverted Capital T
  • Forward-Leaning Capital L
  • Inverted V
  • Lugs and Pegs

Curved Belt Conveyors

This sort of belt conveyor utilizes a curved edge to heft things around corners, make tight exchanges, or augment accessible floor space. These belts’ curves can go up to 180°. Genuine curved conveyors which don’t have any straight runs can just utilize flat belts, as modular plastic belts require straight pursues previously and curves. Curved belt conveyors are frequently utilized in sack taking care of systems to alter things’ passing on course.

Incline/Decline Belt Conveyors

Incline belt conveyors are handy for conveying items up or down. These systems can traverse with cleated belt conveyors to ship items to various heights while shielding them from tumbling off the line. Beside moving items between floors, these conveyor belts are likewise appropriate for boosting gravity stream systems.

Special Type of Conveyor Belts

If you have any special need and above conveyors cannot cater to your requirement, there are several other types of conveyor belts few are listed below:

  • Fiberglass belts
  • Narrow-width conveyors
  • Back-lit belts
  • Vacuum belts
  • Magnetic belts
  • Sandwich belt conveyors

The Microwave Dryer for Drying of Chemical Powder

Microwave technology is not new in heating/drying industries, the concept of using the microwave for heating and cooking is old enough, however, the application of microwave for drying application is relatively new and gaining huge popularity with the number of features and advantages offered. We, at Kerone are amongst the first few organizations that had started advocating about the advantageous application of microwave drying systems either as supporting systems or full-fledged systems.

What is microwave drying? In simple, words microwave dryers are the dryers that utilize microwave energy, produced by the cavity magnetrons in the form of high-speed electromagnetic waves. When these waves collide with the water molecules within material it energies them and result in the production of heat in very less time. This process of heat generation had gained huge popularity since it generates a massive amount of controlled heat with very lesser input. The amount of heat dissipated is easily controllable with the use of microwaves.

Chemical industries are also not untouched with the advantages that microwave bring in however the adoption rate has been slow due to the nature of chemical material being dried, Chemical powders are temperature sensitive thus, drying situations are primarily dictated by rigorous quality standards. The powder drying process requires liquid or slurry material to be drying through applying heat so that it changes its form and converts to powder by losing water in evaporation.

The chemical powder drying process is usually the last step before it being packed. Most chemical powders are temperature sensitive, hence it required to dry at a lower temperature to avoid degradation. Kerone’s microwave drying system helps to overcome this problem by reducing the moisture content at a lower temperature (80-90°C)without harming any product quality.A significant reduction in drying time in microwave drying is often accompanied by an improvement in product quality, making it a promising drying technology. About,95% of the surfaces of the machine are made of stainless steel. It adopts advanced technologies such as a PLC control system, temperature control system, camera monitoring system, automatic feeding system, and other high-end technologies used.

Feature of Microwave chemical dryer developed by Kerone:

  • High-Quality Magnetron manufactured by Panasonic(Japan)/IBF(Germany)/Hitachi (Japan).
  • PID Indicator/controller
  • RF/MW choke/timer provision
  • Stainless steel chamber
  • Required electrical & thermal safety features for microwave generator
  • Variable frequency (Belt speed control)
  • Variable Power output (selectable) up to 100%
  • Temperature Control
  • Controls can be Custom built specifically to your environment, target substances.
  • Operation panel that is full of ease.
  • Design that helps for safe and easy operation and maintenance.
  • Minimized radio field leakage, made to international standards.
  • Pre-programmable Timer on the display for added ease and to avoid losses due to excess heating.

Advantages of using Microwave:

  • The microwave heating process is clean and no emission of any gases or residuals.
  • Microwave heat penetrates both on the surface as well as internally within the object placed for the Treatment.
  • The high speed of heating reduces the total time of processing.
  • The microwave heating process is highly controllable.
  • The workspace requirement is very less.
  • Best drying results are achieved as healing takes place from within the material.
  • The cost of production with microwave dryers are lesser than airflow or direct heat transfer based dryers.

Kerone’s Chemical power dryers are highly customizable and configurable:

  • Microwave Power: Adjustable but commonly range from 0-60kw.
  • Dimension: 100% customizable
  • Width of Belt: 100% customizable depending on the material to be carried
  • Height of Hopper input material:Customized but might range from 150~50mm
  • Working Frequency: 2450MHz±50Hz can be customized with the type of Magnetron
  • Working Temperature: Vary based on the material to be dried, ~5~55oC
  • Control Method: PLC and advanced touch panel
  • Conveyor Speed: Adjustable

We at KERONE have experience of 40+ years in helping the industries with their heating needs, as drying in chemical industries are very important and critical step hence type of heat treatment and selection of the proper drying system is very critical, we at KERONE is have a team of experts to help you with your need of microwave-based drying system from our wide experience. For any query write us at info@kerone.com or visit www.kerone.com.

Fruit and Vegetable Drying

Harvesting fruits and vegetables are hard efforts put by farmers, but maintaining it even equally difficult for them to reach from farm to plates. Maintaining a nutrition level is critical; the way to maintain is keeping fruits and vegetables fresh as low temperatures, which is not an easy task especially in the long supply chain. Mainly in developing countries, this becomes challenging to maintain the low temperature every time this results in the contamination of these fruits and vegetables. This such cases Drying comes in recuse, it is the oldest and most effective method of lowering water content to slow down food spoilage by micro-organisms.

Drying, dehydrating, and dewatering are terms used interchangeably. However, they can be differentiated by the level of water removed. Drying of food material occurs when water vapor is removed from its surface into the surrounding space, resulting in a relatively dried form of the material. In the process of dewatering,water is drained or squeezed out of the material. On the other hand dehydration evaporation of water takes place initially the surface water (external diffusion) then from the interior surface of raw material (internal diffusion). Shelf of dried food items was large than the non-dried one. The shift in focus of drying agriculture products has resulted in sophisticated drying/dewatering/dehydrating machines that are developing high quality dried fruits and vegetables.

There has been tremendous advancement in the process of food and vegetable drying, the plethora of techniques have been developed and innovated over years, below are summary of few of commonly developed techniques, they can be classified in 4 generations:

  • Tray Dryer : Tray dryers are amongst the oldest drying equipment, find application in agriculture dehydrating and drying.A tray dryer is an enclosed rectangular chamber in which trays are placed one below the other in a rack-type structure. The material to be dried is placed in a tray and the hot air is circulated in the chamber. The walls of the chamber are insulated properly to avoid any type of environmental heat loss. Hot air is continuously circulated within the chamber; convection heating takes place to remove the moisture contains from the wet material placed in trays. Blower fans are mounted within the chamber to ensure proper circulation and transfer of heat. The Control panel is fitted on the outer body of the chamber to control the temperature and drying speed.
  • Cabinet Dryer : This one of the simplest types of the dryer, the name is given due to the enclosure provided for drying, where the material to be loaded in trays or trolley. Hot air is released from top or bottom even from side walls in some cases.
  • Tunnel Dryers : Tunnel dryers brought huge changes and advantages into the food industry when brought in first in the early ’90s. These dryers are an advanced version of tray and cabinet dryers, it had capability where material placed in tray or trolley moved automatically through the tunnel.The material to be dried is fed from one end in the air heated tunnel for drying and collected from the other end. The name is derived due to its construction which looks like a tunnel. In tunnel dryer based on the selection of technology, the drying process can be completed while material transfers through a tunnel. Tunnel dryer commonly combined with the hot air as the source of drying of material, however, the advancement in the heating technology has enabled the tunnel dryer with advanced and faster drying techniques such as microwave/ RF/ Infrared. Typically tunnel consist of a door at one end that opened as closes when a material is to be fed, when a trolley is pushed or traveled in the tunnel then door get closed and the hot air is circulated within the tunnel with the help of fans, on completion of the drying process the outlet gate opens and the material is collected. Air movement, circulation, and heating methods vary in tunnel dryers. Three different arrangements, namely, counterflow, parallel flow, and combined flow.
  • Drum Dryer : The drum dryer is very flexible in nature, its operation depends on the pressure of steam within the drum, speed of drum rotation, a width of an applicator, and the ratio of drum speed rotations. All these parameters can by a control/ regulated independently without any dependency on each other. A typical value of the drum dryer components ranges from steam pressure in the drum from 29 to 115 psi, rotation speed can vary from 2 to 30 rpm, thin sheet applicator width can be designed from 0.05 to 0.5 mm, and the ratio of drum rotation speed is from 1 to 5. Feed application in the single drum was dipping, splashing, spraying, and bottom feed roll. The feeding method is generally based on the viscosity of the feed. The drum drying parameters such as drying temperature, feed rate, rotation speed, feed concentration, and surrounding air condition are influential to the attributes of drum-dried food such as particle size, bulk density, moisture content, and solubility.
  • Spray Dryer : Spray drying is a method of dehydrating fluids, solutions, and thin slurries, it converts the fluids or slurries to powder form. Liquid or slurry material to be dehydrated is sprayed in the form of a fine droplet dispersion into the hot airstream. Both air and material either travel in parallel or counterflow. Drying in a spray dryer occurs at a very fast rate so that the contact of material to heat is not for a longer time hence its does not damage the heat selectivity materials and becomes ideal for drying such materials.
  • Fluidized Bed Dryers : Fluidized bed dryer provided the good solid mixing, high rate of heat and mass transfer and transportation of material. The fluidized bed dryer is more suitable for the drying of fine powder particle sizing from 10 to 2000 mm as compared to other conventional drying methods. A fluidized bed is achieved by passing a gas stream from the bottom of a bed of particulate solids. At the low velocity of the gas, the bed stays in a static condition, and the particles lay on a gas distributor plate. The fluidizing gas passes through the distributor and it is uniformly distributed across the bed. The gas velocity is increased such that to achieve the fluidization of bed, the gas velocity at which the bed achieves the fluidization is known as minimum fluidization velocity. A Fluidised bed dryer operates at a gas velocity higher than the minimum fluidization velocity of material under processing. This increase in the gas velocity result in the suspension of particles under processing in air, this appears as the boiling of solid particles of material under processing.
  • Freeze dryer : Freeze-drying, also known as lyophilization or cryodesiccation, is the process of sublimation of ice from frozen material at reduced pressure. This is in opposition to other methods of dehydrating where the heat used to evaporate the water.
  • Vacuum Dryer: In the vacuum drying process, the object to be dried is placed in an enclosed container to vent air and reduce the pressure by using vacuum pumps to increase the water vapor partial pressure difference. Early development of vacuum technology was done in conjunction with the freeze-drying for drying of various foods.Vacuum dryers have no air within hence there is no air pressure, so absolute pressure developed is water pressure.
  • Microwave Dryer : Microwave based industrial dryers have been answered too many of such industrial drying application, it utilizes high-frequency electromagnetic waves that penetrate through the material and results in mobilizing the molecules from within which helps in achieving the goal of drying at a very faster rate. Microwave is not a type of heat, rather it’s a form of energy that is exhibited as heat by the means if their interaction with the material. It results in material to heat themselves, the mechanism of energy conversion used is dipole rotation. In Dipolar rotation is forced processing that happens within the material, many molecules such as water are having asymmetric i.e. they are randomly oriented being in relaxed (zero) state.
  • Infrared Dryer : Infrared (IR) dryers are modern-day industrial drying solutions for material surface, Infrared (IR) dryer uses the infrared radiations, and Infrared radiations are invisible electromagnetic radiation whose wavelength is longer than the visible light wave range between 0.78 and 1000 µm. This type of radiation has characteristic to transfer thermal energy from warmer objects to cooler objects. The desired heat is produced at the surface of the targeted material; heat is produced on the surface by matching the infrared emission spectrum of the radiator to the absorption capacity of a material.

Agriculture and food safety has always been prime focused industry, due to increasing population and shrinking farming land, food safety has gained even more attention than ever before. Drying plays a vital role in keeping food items used for a longer period, hence this is a very important industry. We, companies such as Kerone always strive to achieve the best possible technology to support the agriculture and fruit and vegetable industry.

Type sterilization and Disinfestation methods that can be used in the Laboratories

Sterilization and Disinfestation processes have gained huge attention and importance in today’s world, where we are continuously seeing increase in number of viruses and bacteria; eliminating these are almost important in any type of process, workplace, medical facilities, laboratories and many others. The current situation around the world has raised this as biggest fight between virus and living being. Everything now needs sterilization to get rid of the various kind of infect-ants, here we will try to put together few of most common but very powerful methods of sterilization. Sterilization can be accomplished by a combination of heat, chemicals, light, high pressure and filtration like steam under tension, dry heat, bright radiation, gas fume sterilants, chlorine dioxide gas and so forth. Compelling sterilization strategies are basic for working in a lab and carelessness of this could prompt extreme results, it could even cost an actual existence.

Heat Method: Heating or warming is one of the most common method for sterilization. Temperature is raised to specified point for duration to kill the microbes in any kind of substances. Increasing heat for a set duration results in killing almost all type of microbes. Based on the type of heat used, heating methods are categorised as:

  • Steam Sterilization (Autoclaves): This one of the most common method for killing germs and bacteria of laboratory apparatus, steam of temperature ranging from 121-134oC under pressure. This is an extremely viable method that kills/deactivates all microbes, bacterial spores and infections. Autoclaving kills microbes by hydrolysis and coagulation of cell proteins, which is proficiently accomplished by extraordinary heat within the sight of water. The extraordinary heat originates from the steam. Pressurized steam has a high inert heat and at 100°C it holds multiple times more heat than water at a similar temperature. As a rule, Autoclaves can be contrasted and a commonplace weight cooker utilized for cooking aside from in the quality that practically all the air is expelled from the autoclave before the heating procedure begins. Wet heat sterilization strategies additionally incorporate boiling and purification.
  • Dry Heat Sterilization: In the process of dry heat sterilization hot air oven or flaming is used, substance to be sterilized are exposed direct flame in case of metallic devices, needles scissors etc. Hot air ovens are suitable for the powders, metals, glass items, ceramic items, etc.
  • Electromagnetic Heat Sterilization: In this type of heating instead of steam or flame, electromagnetic waves such as microwave or RF waves are used. These type of sterilisers are suitable of materials which has water contained in it.

Filtration: Filtration is the fastest method to clean arrangements without applying any heating or chemical processing. This method includes filtering with a pore size that is unreasonably little for microbes to go through. By and large filters with a pore measurement of 0.2 um are utilized for the evacuation of microorganisms. Film filters are all the more commonly utilized filters over sintered or seitz or light filters. It might be noticed that infections and phage are a lot littler than microbes, so the filtration method isn’t appropriate if these are the prime concern.

Radiation sterilization: This method includes uncovering the pressed materials to radiation (UV, X-beams, gamma beams) for sterilization. The fundamental contrast between various radiation types is their infiltration and subsequently their viability. UV beams have low infiltration and along these lines are less viable, yet it is moderately sheltered and can be utilized for little territory sterilization. X-beams and gamma beams have unmistakably additionally infiltrating force and in this way are increasingly successful for sterilization for a huge scope. It is, in any case, progressively hazardous and therefore needs exceptional consideration. UV light is routinely used to clean the insides of organic security cupboards between employments. X-beams are utilized for cleaning enormous bundles and bed heaps of clinical gadgets. Gamma radiation is commonly utilized for sterilization of dispensable clinical hardware, for example, syringes, needles, cannulas and IV sets, and nourishment.

Chemical sterilization: Material which are not suitable or are heat sensitive requires the other type of sterilization processing, such as utilising chemicals those can help in killing all microbes. Chemical method utilizes liquid or gaseous form of chemicals those are toxic for microbes without affecting the materials.

The commonly utilized gases for sterilization are a blend of ethylene oxide and carbon-dioxide. Here Carbon dioxide is added to limit the odds of a blast. Ozone gas is another choice which oxidize most natural issue. Hydrogen peroxide, Nitrogen dioxide, Glutaraldehyde and formaldehyde arrangements, Phthalaldehyde, and Peracetic corrosive are different instances of chemicals utilized for sterilization. Ethanol and IPA are acceptable at killing microbial cells, however they have no impact on spores.

Medical Waste Treatment

Health care facilities such as hospitals, clinics, maternity homes and pathology labs are very critical for society. These facilities are responsible treatment and keeping wellbeing but on the other side there is lot of waste that gets generated by them, these waste as very critical to handle is they can have even worst effect than what service these health facilities provide. Due to increasing demand of medical related kits and products there is demand of managing the waste created out of it, the best approach that followed for any waste management Reduce, Recycle, Reuse and dispose responsibly, always not applicable in sense of medical, we cannot reduce the consumption but other measures can be used.


Medical and bio wastes need careful treatment and disposal as they might result in some type of disease or can result in very adverse effect of all kind of living creatures. Treating all type of medical wastes in best possible way in only option that remains, hence segregation of becomes key for success of waste treatment. Below are some of the key thermal treatments:

• Incineration:
Incineration is typically used for pathological and pharmaceutical waste. Incineration is a high-temperature dry oxidation process that reduces organic and combustible waste to inorganic, incombustible matter and results in a very significant reduction of waste volume and weight. Incineration of medical waste should be performed in a controlled facility to ensure complete combustion and minimize any negative effects for the environment. This process is usually selected to treat wastes that cannot be recycled,reused, or disposed of in a landfill site.
There are three type of incineration methods:

  1. Double-chamber pyrolytic incinerators
  2. Single-chamber furnaces with static grate
  3. Rotary kilns

Autoclaving:
Majority of medical wastes are suitable of the process of autoclaving before any further processing on them. In simple word, autoclaving is simply a process of steam sterilization, this thermal treatment is typically used for the sharp and certain other types of infectious process. In this process, wastes to be sterilized are placed inside the large pressure cooker like chamber and steam is fed in to it for specific period of and at pressure, this results in killing of microorganisms. This process is typically used before disposal.

Autoclaving, which is also known simply as steam sterilization, is the most commonly utilized alternative to incineration. It is both less costly and carries no documented health impacts. In this method, wastes are sterilized or disinfected prior to disposal in a landfill. Bags of waste are placed in a chamber and steam is introduced for a determined period of time at a specified pressure and temperature. This assures the destruction of microorganisms.

Modern aged autoclaves are now automated to minimize the human intervention and risk. However, many medical wastes such as chemical waste, including chemotherapy (radioactive) waste, as well as pharmaceutical waste can’t be disinfected in an autoclave.

Microwave based sterilization
Microwave with frequency of 2450Mhz results in destruction of almost all microorganisms. The water contains within the waste to be treated helps rapid heating of and destruction of infectious components. Microwave penetrates within the waste and results in disinfestation from within as well. Since microwave as more suitable for the treatment of semi-solid or the one which contains some amount of water within, hence to get best results sometimes wastes are first mixed with water or grinded and then mixed with water. Microwave based systems could be a potential substitute of autoclaving.

Thermal inactivation
Many medical wastes those cannot be treated with the microwave or other mentioned thermal techniques above are treated by using conventional heating systems such as drum heating and etc. In this process waste is heated to temperatures where infectious agents are destroyed. Potentially used for treating liquid wastes.

Handle it with care – Material Handling for heat processing systems

Heating generating system in any heat processing systems may be perceived as heart of system. But do you thing only heart is sufficient to for successful operation of any kind of heat processing, along with heart the hand and mouth is important too. You might be wondering why I am talking about heart, hand, mouth and what is hand and mouth in processing systems. The Material handling systems are the hand and mouth of heating system as these material handling mechanism feeds the heating processing systems with the material being processed. Hence, the selection of proper handling system is required.
The selection of the material handling system relies on the multiple factors:

  • Properties of Material
  • Mode of operation of heating system
  • Type of Energy
  • Exhaust system
  • Output material post processing

Material Handing process deals with the how the material is feed-in, handled, and moved out of the system. We are trying to list and introduce you to few of the material handling systems:

  • Flow through System:Heating application those requires the processing of materials such asvapour, or slurry to be pushed through tubes, pipes, or ducts positioned within the heating system by using pumps or blowers.
  • Conveyored system with belt, bucket or roller:Heating application those requires material to transported through the heating system during process. Sometime materials are moved on surface of conveyor or place with in any containers. The work piece is moved through the furnace on driven belts or rolls.
  • Rotary ovens or heaters:Heating application those requires material to transported through a revolving drum or barrel while being heated or dried by direct-fired burners or by indirect heating from an oven shell.
  • Vertical shaft furnace systems:Heating application those requires material to transported from top to bottom using gravitational forceat time of processing by direct contact.
  • Walking beam furnaces: The material under processing is “walked” from side to side in oven by means of distinctive beams. The furnaces are typically direct-fired with many type of fire zone from top and bottom.
  • Car bottom heaters:In this heating application the material is placed on a movable support that travels through the oven or is placed in an oven for heating.
  • Continuous strip furnace systems. Systems in which the material in the form of a sheet or strip travels through a furnace in horizontal or vertical direction while being heated and cooled. The material heating could be by direct contact with hot gases or by radiation from the heated “walls” of the furnace.
  • Vertical material handling systems: Heating application those requires material to transportedvertically against the gravity from bottom to top. The material is persistent by a vertical material handling system and processed while it’s been loaded.

We are Kerone have more than 4 decades’ experience in helping our customers with best heat processing systems. Below are the few features of Materials Handling systems built and designed by us:

Features:

  • High performance
  • Highly controllable
  • Built with the high quality stainless steel material or special Alloys
  • Highly customizable.
  • Corrosion free
  • Tailor made to fit your requirements.
  • Easy functions
  • Very efficient

You can reach out us on www.kerone.com or write of us on info@kerone.com for any question that distressing while making critical selection of heat processing systems.

Switching from one heat processing systems to other

New technology and technically advanced systems and process machineries will be any time better than the traditional processes, this has been common perspective of the everyone and the same is not wrong too. However, there has been the cases where you might find new age technology has been lagged in performance over technically/technologically improved traditional systems, though the proportion is less but this is reality. Advancing to new age technology such as IR (Infrared) or microwave heating/drying are always an appreciable decision. These new age heating, there are not very new have significantly large number of successful installations up and running, have proved that these technologies have plethora advantages over others few of them are:

  • Easy to operate
  • Highly controllable
  • Low turnaround time
  • Low/No warm-up lag
  • High efficiency
  • Low Emission/ heat loss
  • Can take benefit of AI, iOT and ML
  • Precise heating and control
  • And Many more.

All above advantages/benefits are very provoking to get rid-off you existing conventional heater and have these new heating systems installed that will give best quality product in no time. This is great thought but not very true for every type of application and process need, what we appeal as customer centric organization is important to stop for a while to ponder about few of the critical points:

  • What advantages will the new technology heaters/dryers will bring along in my current process?
  • Will it help in reducing the total processing cycle time, even if yes how much?
  • What will be the type of materials to be processed?
  • What is the physical, physiochemical property, absorptivity, Size, Microstructure and Optical Properties of material?
  • Will the material able to respond to IR or Microwave radiation in best way?
  • Can the existing heating/drying system be used?
  • What if we use new systems as extension to existing one?
  • What will be the space requirement for the new installation?
  • Can we have new improved version of traditional giving better results?

There might be thousands of more such questions or concerns that can arise in your mind if you think of such changes. But the first and foremost important aspect is material that needs to be processed and desired quality of output in association with the time to process. Key things could be:

  • Structure of material
  • Radio Activeness
  • Absorbing capability
  • Scattering capacity
  • Size of particle within the material
  • Microstructure of material
  • Thickness, chemical properties
  • Refraction and reflection capacity

The approach is to get sample of material processed in similar environment as of yours, in different type of heating/drying system. If you are looking for any of such then reach out to Kerone’s, KeroneResearch and Development lab dedicate to help its customers with best solution test before making any decision. Reach out to us for getting you samples tested before making final decision.

Role of heating systems in the process of sterilization

Bacteria, viruses and enzymes are inseparable part of food, milk, chemical and other many processing industries. However, the struggle has always been to protect from them, there could be plethora of reasons why these bacteria, viruses and enzymes needs to be killed/eliminated either for increasing the life, avoiding contamination, stop viral infection and many more. This process is very commonly known as sterilization. Sterilization can be attained by the multiple ways such as heating, irradiation, and filtration and by the way of chemical reactions, amongst all the sterilization processes the heat processing is one of the oldest and proven support processing system.

With advancement of technology and processing systems, the sterilization process has become more efficient and cost effective. There are many other processes across various industries that which we some time get puzzled with such as disinfection, sanitization, pasteurization and etc, but these processes are completely different from the sterilization, though, the basic purpose is to kill the contaminating bacteria and viruses.

Heating systems based on advanced technology such as microwave, IR, Radio frequency and hybrid one have showcased very effective results. Now with the new AI and ML based systems can perform both sterilization and drying together unlike old systems where multiple staging was required to achieve the same.

Industries such as medical, pharmaceutical and food are having sterilization as one of their vital process for various applications. Industries those are having sterilization as critical process are:

  1. Medical and Surgical
  2. Pharmaceutical
  3. Chemical
  4. Laboratories
  5. Space crafts
  6. Food
  7. Microbiology and etc.

As I mentioned, sterilization by means of heating is there from ages buts the temperature needs to be risen to a point and kept for specified duration, deflection in any of both might result in not killing all viruses and bacteria or harming/changing the property of material under processing. Heating is very effective way of processing however how to heat is also important, there are flaming and non-flaming heating systems based on suitability of material under processing. Some heat sensitive materials need very precise control on temperature and duration.

Flaming heating is oldest type of the heating, same direct flame of the fire is used to sterilize the subjected material, whereas the other non-flaming heating of sterilization uses the hot air or hot water heating system. The new addition to list has been EM based heaters such as Microwave, IR and RF.

The flame based sterilization was not suitable for the all type of substrates hence the non-flame based heater (dry heat) is started getting popularity, in non-flaming biological agents are killed or made inactive by hot air, since the hot air are not direct heating type hence it does not have that much effectiveness, the electromagnetic based heating systems such as Infrared based haters, Microwave heater and RF heaters has proven their capability both in terms of raising the temperature quickly to deactivate/kill biological agents and suitability to the subject material.

Controlling of heat, time and flow of material is key success criteria for sterilization processing not this but in all heat treatment processing, hence at Kerone we utilize of more than 4 decades’ know-how of heat processing and combining it with the new age AI technologies to achieve better and faster results for type of processing needs. You can reach out to us for any query and enquiries write to us info@kerone.com or visit us at www.kerone.com .

Heating System with inbuilt Intelligence

Thermal treatment is vital processing step in any kind of product processing systems across various industries such as Pharma, Food, Chemical, Fertilizers, Coating, Paint, Ceramic, Electronics and many more. Application of heating system such as heating, drying, sterilization, coating, pasteurization, blanching, mixing and many more; all requires very preciously controlled heating for quality production. But as we all know, every material put under processing may or may not have the same level of moisture or may not require same temperature for processing though being the same type if material also manually adjusting the heating temperature or heating time is also not feasible; Practically!

We as Kerone, have always advocated that the new age thermal treatment systems must be capable of making efficient decision to offer best possible correction based of the input material type its contents and behavior while under processing. This shift is paradigm in industrial thermal treatment from brainless to brained industrial desired. This might have been not possible few decades back however due to advancement of AI, ML and IoT technologies it is achievable to large extend.

Advanced AI and ML can make machines more intelligence with by building the capabilities such as:

Computer Vision:

Precisely trained deep learning model that can detect the minute deflection in the product quality which is even the most experienced workmen cannot find. Cameras are very sensitive compared to human eyes and they can be installed within the machine to detect the flaw within the product under process and take corrective actions. This will be possible by combining the AI and ML together detect early and correct properly.

Digital Twins:

Digital Twins is concept that leverages the power of all three AI, ML and IoT together and help you to be with the machine every time even you are away. Digital twins are exclusively useful when working with equipment from a remote distance. Sensors implanted inside machine gathers data about real-time status, working condition or position and this data can be access via internet and cloud from processing and providing information on your figure tip.

Speech and Text Recognition:

It gets hard to modify the temperature, wind current, speed and so on to the exact an incentive for the ideal yield quality when did physically. With the capacity to identify discourse and content you can converse with new age machines and impart what is required. Some time you don’t have a clue what parameter will bring about best quality handled item, anyway with the AI and ML simply address machine or feed the necessities, it will change over that contribution to the parameters that will be required for best outcome and modify all the hardware to work and accomplish the shared objective.

Predictive maintenance:

Preventive maintenance is not old school thing in contradicted to that we have predictive maintenance. As the machine continuously reports for minute by minute performance is recoded and AI and ML models detects the potential fault and inefficient performances in advance. The AI and ML powered predictive maintenance saves businesses valuable time and resources, including labor costs, while guaranteeing optimal manufacturing performance.

Advantages of system with power to help in making decision:

  • Less Wastage of material.
  • Less and efficient utilization of energy.
  • Fast and precise heating system.
  • Save energy in some case up to 50%.
  • Easy integration with modernized production lines.
  • Understand, monitor, predict and control process variability.
  • Augment equipment and process diagnostics capabilities.
  • Quicker Response time and less operations cost for machine with inbuilt intelligence.
  • Real-time remote monitoring of performance.
  • Multi-site monitoring improving the operational efficiency and reducing the site downtime.
  • Full manufacturing traceability.
  • Predictive Maintenance and quality management.