Kerry Foods, a leading food manufacturer, were facing substantial energy costs associated with their production processes. To address this, they sought to improve the efficiency of their drying process. Having previously worked with Secomak on a similar application, they reached out again for a solution. After consideration we provided Kerry Foods with a 4kW blower system, replacing the existing 18kW system. This case study explores the energy savings and financial benefits experienced over a one-year period with the new Secomak system.

The Challenge

Kerry Foods’ production line involved an 18kW blower system to ensure efficient drying of their pouches once they exited a cooling bath. While effective, the system was energy-intensive, leading to high operational costs. The company aimed to reduce energy consumption without compromising the quality and efficiency of their drying process.

The Solution

Secomak proposed a solution involving our 4kW blower system, designed to deliver the same, if not better, drying performance with significantly less power consumption. Key features of our system included:

High Efficiency: The 4kW blower provided powerful airflow with substantially lower energy requirements.

Robust Construction: Durable materials ensured the system could withstand the demanding production environment.

Implementation

The implementation of Secomak’s 4kW blower system involved:

Assessment: Detailed analysis of the existing drying process to tailor the new system to specific requirements.

Installation: Seamless integration of the 4kW blower system into the production line, minimising downtime.

Results

Over a one-year period, the Secomak system delivered significant energy and cost savings for Kerry Foods:

Energy Reduction: The power consumption was reduced from 18kW to 4kW, representing a 78% decrease in energy usage.

Cost Savings: £9,000 in energy costs over the year.

Sustainability: The reduction in energy consumption contributed to Kerry Foods’ sustainability goals by lowering their carbon footprint.

Financial Analysis

The transition to Secomak’s 4kW system resulted in substantial financial benefits:

Initial Investment: The cost of the new 4kW blower system was offset by the energy savings achieved within the first year.

Return on Investment (ROI): The £9,000 annual savings translated to a rapid payback period, making the investment highly cost-effective.

Ongoing Savings: Continued use of the Secomak system will result in ongoing annual savings, enhancing long-term profitability.

Conclusion

Kerry Foods’ experience with Secomak’s 4kW blower demonstrates the significant impact that efficient industrial equipment can have on energy consumption and operational costs. By replacing their 18kW system, our customer achieved substantial financial savings and supported their sustainability initiatives. Secomak’s commitment to quality and innovation provided a reliable, efficient solution that will continue to benefit their operations for years to come.

Additionally, Kerry Foods were so satisfied with the performance and savings from the first Secomak unit that they have since purchased another system. This further investment underlines their confidence in our solutions and commitment to energy saving.

This case study highlights the potential for energy savings in industrial applications through the adoption of efficient blower technology, showcasing Secomak as a leader in providing sustainable and cost-effective solutions.

The challenge? Preheating a 450kg aerospace-grade copper component before precision welding. This is a crucial step in the process, as it:

• Prevents cracking by controlling cooling rates and reducing thermal stress
• Minimises residual stress and distortion, helping to ensure a strong and stable weld
• Encourages hydrogen diffusion, which reduces the risk of defects during welding

From 5 Hours to Just 1 Hour — A 400 Percent Improvement

Originally, the heating process took up to five hours, creating a bottleneck in production. Working closely with the customer, our Sales, Engineering and Technical Controls teams designed a bespoke 36kW HeatPack system that brought that down to just one hour. That’s a fourfold improvement in heating efficiency.

This was a carefully engineered solution that prioritised performance, reliability and safety.

What Made the HeatPack the Right Choice

The HeatPack system used in this project was specially adapted for aerospace use, delivering the precision and control needed for such a high-spec application. Some key features of our heatpack included:

• Precision heating with hot air up to 400°C and temperature accuracy within ±1°C, thanks to advanced PID control and a solid-state relay pulsing 1000 times per second• Smart energy use through precise
• temperature control and an optional Variable Speed Drive for airflow regulation, helping to reduce running costs
• Industrial-grade reliability with direct drive blowers and fast-responding heaters built for continuous use without maintenance
• Safety built in, including a high-temperature cut-off, adjustable alarms and the option for an HMI for enhanced control and monitoring
• Recirculation capability to reuse hot air, cutting down energy demand and improving overall efficiency
• Flexible setup, with a full range of accessories and an optional trolley with lockable castors for easier transport and integration on site

What the Customer Had to Say

“Very impressed and thank you all for the support.”
“Wanted to update that the machine has been working terrific.”

Feedback like this reminds us why we do what we do, and how a well-engineered solution can have a real impact on productivity.

Engineering Better Outcomes

This project is just one example of how Secomak’s HeatPack technology is helping customers work faster, smarter and more efficiently, even in the most demanding industries.

Interested in learning more?

Get in touch with Secomak today to find out how our HeatPack range can support your operation. contact

Since the inception of our partnership in 2020, Secomak and SKF have embarked on a transformative journey to innovate and redefine bearing technology. This strategic collaboration has culminated in development of our new hybrid ceramic “Long-Life Bearing Assembly“, setting new industry standards for performance, reliability and maintenance-free operation.

Genesis of the Partnership

In 2020, Secomak, renowned for their advanced industrial solutions, identified a critical need for their equipment line-up: a bearing that could significantly extend operational runtime while eliminating the need for regular maintenance. Recognising SKF’s unparalleled expertise in bearing technology, Secomak sough a collaborative partnership to tackle this ambitious project.

Development Milestones

Research and initial Design

The Journey began with a comprehensive research phase. SKF’s team of engineers and materials scientists collaborated closely

with Secomak’s product development experts to understand the specific demands and operating conditions of Secomak’s applications. This phase involved:

• In-depth Analysis: Evaluating existing bearing performance data and identifying areas of improvement.
• Material selection: Exploring advanced materials, particularly ceramics, known for their high durability, resistance to wear and tear and reduced friction properties.
• Computer Aided Design (CAD): Utilising the latest CAD software to develop and perfect the key design principles.

Prototyping and Testing

 Following the research phase, SKF and Secomak moved into the prototyping stage. This critical phase involved:

• Design
  Iterations: Creating multiple prototypes with varying compositions and configurations to identify optimal design.
• Rigorous Testing: Subjecting the prototypes to extensive laboratory and field tests to evaluate performance under real-world conditions. Key performance indicators included load capacity, rotational speed, temperature stability, and wear resistance. 

Breakthrough Achievements

 Increased Runtime

One of the most significant achievements of the hybrid ceramic bearings is the remarkable increase in operational runtime. Our bearings offer at least a 50% increase, extending the runtime to an extraordinary 30,000 hours and beyond. This milestone is a direct result of:

• Material Superiority: The use of hybrid ceramics, which combine the strength of steel with the resilience of ceramic materials, ensuring superior performance and longevity.
• Innovative Engineering: Advanced design techniques that optimise load distribution and reduce friction, leading to less wear and extended service life.

Maintenance-Free Operation

Another ground-breaking feature of the new bearings is the elimination of lubrication requirements. This innovation translates to:

• Zero Maintenance: Removing the need for regular lubrication checks and replacements, drastically reducing maintenance costs and downtime.
• Enhance Cleanliness: Particularly beneficial in industries such as food and beverage or pharmaceuticals, where contamination from lubricants must be avoided.

Sustainability Benefits

Sustainability is a core value for both Secomak and SKF, and the hybrid ceramic bearings are a testament to this commitment. The bearings offer several significant sustainability benefits:

Reduced Material and Waste

• Elimination of Lubricants: Traditional bearings require regular lubrication, leading to the consumption of significant amounts of grease and oil over their lifespan. The hybrid ceramic bearings eliminate the need for these lubricants, reducing environmental contamination and waste associated with their production, application, and disposal.
• Minimised Waste Generation: With a dramatically extended operational life, the frequency of bearing replacements is reduced, leading to less waste from discarded bearings. This contributes to a reduction in the overall environmental footprint of the equipment.

Decreased Maintenance and Downtime

• Resource Efficiency: Less frequent maintenance means fewer resources are used for bearing replacements and associated activities. This includes reduced use of tools, transportation, and human resources, all contributing to a lower environmental impact.
• Operational Efficiency: By minimising downtime for maintenance, the equipment can operate more continuously and efficiently, leading to higher productivity and better utilisation of resources.

 Increased Efficiency 

• Energy Savings: The Hybrid ceramic bearings are designed to reduce friction significantly. Lower friction means less energy is required to operate machinery, translating to substantial energy saving over time. This reduction not only lowers operational costs but also decreases greenhouse gas emissions associated with energy production.
• Improved performance: Enhanced efficiency and reliability ensures that machinery operates at optimal performance levels, further contributing to energy savings and reducing the overall carbon footprint.

In recognition of the reliability and durability of the newly developed hybrid ceramic bearing assembly, Secomak are confidently offering an extended three-year warranty. This extended warranty underscores:

• Product Confidence: Our rigorous quality control and extensive testing ensure that each bearing meets the highest standards.
• Customer Assurance: Providing Secomak’s customers with added peace of mind and long-term value.

Collaboration and Innovation

The success of this partnership can be attributed to synergy between SKF and Secomak, characterised by:

• Joint Expertise: Leveraging SKF’s deep knowledge in bearing technology and materials science with Secomak’s industry-specific insights and customer requirements.
• Innovative Culture: Both organisations are committed to pushing the boundaries of innovation, fostering a collaborative environment that encourages creative problem-solving and technological advancements.
• Customer-Centric Approach: Continuous engagement with end-users to ensure the final product meets and exceeds their expectations, driving improvements based on real-world feedback.

Future Prospects

While the current achievements are impressive, SKF and Secomak are not resting on their laurels, the potential for further performance enhancements remains substantial. Together our R&D efforts will be focused on:

• Material Advancement: Exploring next generation ceramic materials that could offer even greater durability and performance.
• Design Refinements: Continuous optimisation of bearing design to achieve higher efficiency and reliability.
• Smart Technology Integration: Investigating the incorporation of sensors and IoT capabilities for real-time monitoring and predictive maintenance.
• Higher speed: whilst the initial developments have focused on efficiency and reliability enhancements. The new development paves the way for future performance enhancements with the potential for significant increases in RPM, with bearings running as much as 34% faster.

Industry Recognition

The strength and innovation of the SKF and Secomak partnership have garnered industry attention. We are excited to announce our application for the prestigious Automate Awards for Partnership pf the year. This award recognises the most effective and impactful collaborations within the industry. Winning this award would be a testament to the exceptional results achieved through partnership.

Conclusion

The partnership between Secomak and SKF exemplifies the transformative power of collaboration in driving technological advancements. The development of hybrid ceramic bearings marks a significant lead forward in bearing technology, delivering unparalleled performance and reliability. As we look to the future, SKF remains committed to innovation, confident that our ongoing collaboration with Secomak will continue to set new benchmarks in the industry.

This partnership not only highlights the strength of both organisations but also sets a new standard for excellence in engineering and industrial solutions. Together, Secomak and SKF are pioneering the future of hybrid ceramic bearings, providing unmatched value and performance for our customers.

Sun Magic Juices, a leading producer of high-quality fruit juices, faced a significant challenge in their production line. Secomak supplied Sun Magic Juices with a 4kW blower and air knife system designed to dry the bottles after sterilization. Also the customer wanted to dry bags of orange peel after shrinking. This case study explores the problem, the solution implemented, and the resulting benefits. The customer have an existing relationship with Secomak as they have a DryGuide machine on another line.

The Application

In the packaging process of the Orange juice, the product is labelled, filled and capped before sterilization. At this point the bottle has moisture on it that needs to be removed. The orange peel is steam shrinked which again means there is excess moisture on the product that needs to be removed prior to packaging.

The Challenge

The challenge was to dry the bottles as much as possible before they were packaged. The product would travel in groups, up on a short conveyor and then join a larger conveyor. The aim was to dry these bottles at various parts of the conveyor to cover all parts of the bottle.

The second challenge was to remove excess moisture from steam shrinked bags of orange peel. There was an excessive amount of water on this product making it hard to dry and the main focus was to remove as much as possible to help with process improvements. This again would be achieved with air knives on a mobile conveyor powered by the same Secomak 492blower.

The Impact of Secomak’s Equipment

The equipment supplied means the bottles and orange peel will be considerably drier when being moved to the cardboard packaging. This will mean more reliable packaging and less concerns for Sun Magic Juices.

By adding this system to the line it is another example where Secomak has helped with process improvements for a beverage manufacturer.

GSK, a global leader in pharmaceuticals, faced challenges in efficiently drying Intermediate Bulk Containers (IBCs) after washing. The manual drying process was time-consuming and labour-intensive. To streamline operations, GSK partnered with Secomak to implement an automated drying solution using Secomak’s advanced 9kW HeatPack systems. This case study examines the benefits and improvements achieved through this collaboration.

Background

GSK had previously used a Secomak Heatpack at their Worthing site, which had operated without interruption for over 20 years. This reliability and performance set a high standard, prompting a return to Secomak for their new investment.

The Challenge

GSK’s existing process for drying IBCs involved manual labour, with operators hand-drying each container. This method was not only inefficient but also inconsistent, leading to potential quality issues. GSK required a solution that could:

1. Reduce Drying Time: Accelerate the drying process to enhance productivity.
2. Ensure Consistent Results: Achieve uniform drying to maintain high-quality standards.
3. Automate Operations: Minimise manual intervention to save time and labour costs.

The Solution

Secomak provided two 9kW HeatPack units, specifically designed to meet the rigorous demands of pharmaceutical applications. The HeatPacks included advanced control systems, featuring:

• Lockable HMI: A user-friendly interface that can be locked to prevent unauthorised adjustments.
• Heat Trend Lines: Real-time monitoring of temperature trends to ensure optimal drying conditions.
• Temperature Cut-Outs: Adjustable over and under temperature cut-outs to prevent overheating or underheating.
• Alarm History: A recorded history of alarms for troubleshooting and maintaining operational efficiency.

These features provided GSK with a reliable and efficient drying solution, transforming their IBC drying process.

Accurate Temperature Control and Efficiency

One of the standout features of Secomak’s 9kW HeatPack is its ability to accurately control temperature to within 1%. This precise control is crucial for maintaining the integrity and quality of pharmaceutical products. The HeatPacks utilise Secomak manufactured heaters and blowers, ensuring high performance and efficiency. These components are designed to deliver maximum heat output with minimal energy consumption, making the system extremely efficient and cost-effective.

Implementation

The implementation process involved:

1. Installation: Integrating the two 9kW HeatPack units into GSK’s existing workflow with minimal disruption.
2. Training: Providing comprehensive training for operators on using the new systems effectively.
3. Optimisation: Fine-tuning the systems to achieve the best drying performance tailored to specific needs.

Our commitment to customer service was evident with engineering support included for the installation, commissioning, and training of the operational team. This hands-on approach ensured a smooth transition and immediate operational benefits.

Results

The introduction of Secomak’s 9kW HeatPacks brought significant improvements to GSK’s operations:

• Time Savings: The automated system reduced the drying time of IBCs from several hours to just 5 minutes, greatly enhancing productivity.
• Labour Savings: By eliminating the need for manual drying, our customer was able to reallocate labour resources to more critical tasks.
• Consistent Drying: The advanced controls ensured each IBC was dried uniformly, maintaining high-quality standards.
• Operational Efficiency: The recorded history of alarms and real-time monitoring allowed for proactive maintenance and reduced downtime.

Financial Analysis

The investment in Secomak’s 9kW HeatPacks yielded substantial financial benefits for GSK:

• Labor Cost Reduction: Significant savings from reallocated manual labour.
• Increased Throughput: Faster drying times allowed for more batches to be processed, increasing overall production capacity.
• Quality Assurance: Consistent drying reduced the risk of quality issues, leading to fewer rejects and reworks.

Customer Satisfaction

GSK expressed high satisfaction with Secomak’s customer service. The proactive approach, including on-site visits to the Worthing facility for installation, commissioning, and comprehensive training, was greatly appreciated. This level of service ensured that GSK’s team could confidently operate and maintain the new systems, maximising the benefits of the HeatPacks.

Conclusion

The implementation of Secomak’s 9kW HeatPacks at GSK exemplifies how advanced industrial heating solutions can transform pharmaceutical manufacturing processes. By automating the drying of IBCs, GSK achieved time and labour savings while ensuring consistent and reliable drying performance. The precise temperature control and efficiency of the HeatPacks, combined with our commitment to customer service, underlined the success of this project.

The decision to invest in two new Heatpacks was part of a multimillion-pound investment at the Worthing site, reinforcing GSK’s commitment to leveraging reliable and innovative solutions for operational excellence. This case study highlights the potential for significant operational improvements and cost savings through the use of advanced heating technologies, positioning Secomak as a trusted partner in enhancing industrial processes.

Johnson & Johnson, a well-recognised homecare brand.

Many of us have used their products in our lifetime, but not all of us will know the diversity of products J&J manufacture. In this instance Secomak worked closely with J&J Vision Care, producers of over 1 million contact lenses each day.

The Application

In the manufacturing process of the contact lenses the Secomak unit is used to remove excess water from product prior to being hygienically sealed and packaged.

The Challenge

The challenge when we recently visited Johnson & Johnson was to supply a breakdown of critical spare parts which their Engineers can keep on the shelves in case of a breakdown.

While on site we learned the existing Secomak units running had very little spares stock, over the years many lines had the same blower units fitted with minimal downtime events noted. When a failure of one of the Secomak units in operation occurred the reality of the lack of spares in house came to light.
Many of the units in operation were 20 years old which presented its own challenge. J&J required an option for a replacement blower and motor as well as spare parts. Our Engineers designed a unit which can be retrofitted into the existing enclosures which will minimise costs and downtime if a replacement is necessary.

The Impact of Secomak’s Equipment

The impact of our equipment was evident to see. Each line ran 24/7 for up to 20 years with very impressive reliability. Only when a review of aged units within the factory was conducted did a requirement come to light for stocked spare parts. It’s testament to our quality and reliability that production has ran smoothly over these years which allowed J&J to focus on other areas of their business.

The customer specialises in aerospace, defence, and security. They innovate across five divisions, including Helicopters, Aircraft, Aerostructures, Electronics and Cybersecurity.

One of the leaders in defence technology, they employ over 50k people worldwide.

The Challenge

The customer needed to test aircraft transmission systems in a consistent environment that was easy to replicate every time.

Using a specific type of Test Bed Torquemeter, they needed to pass air across a surface at high speed, forming a seal. If transmission speed of the aircraft exceeded a set amount, this aerodynamic seal was required for testing to be relevant and accurate.

Multiple test rigs are used for this purpose, and a product that supplied consistent high pressure air on demand was critical for this application.

The Solution

The Secomak Model 428 Belt-Driven High Speed Fan was selected for use with the customer’s test rigs. Testing aircraft transmission systems demanded that the air pressure was consistent for accurate results and data benchmarking.

The Model 428 provides a reliable and consistent pressure boost for extended periods. Testing for roughly 2 to 3 hours at a time, the Model 428 Blower can supply the required pressure multiple times over.

The Benefits

Consistent high pressure is the single greatest benefit of the Model 428. Allowing the customer to benchmark and test their aircraft transmission systems in the same conditions every time.

Secomak’s Belt-Driven Centrifugal Fan technology ensures reliability, with minimal maintenance required. Replacement belts are inexpensive and simple to change, minimising downtime and making sure it is easy to schedule by the customer.

The blower has excellent IE3 motor efficiency for low energy consumption, combined with a compact footprint, granting greater flexibility to the customer to position it wherever needed.

Secomak are supplying an industry leader in print drying technology, who themselves then deliver this solution to the end user.

This end user excels in automation stationary printing, which required a print drying solution to meet and exceed the demands of continuous printing.

The Challenge

As production speeds have progressively increased, stationary printing has required faster, more efficient and more precise drying applications.

The end user required a more specific customisable solution, that was more efficient and consistent across its operating window. The drying solution had to be effective very quickly from power on and maintain peak performance throughout that production cycle.

These flexible requirements had to be combined with a small footprint and industry leading reliability, with installations often being challenged to operate for thousands of hours without requiring inspection or service.

The Solution

For over 90 years and across a wide variety of projects, Secomak’s range of high-speed fans and process heaters have been engineered and constantly improved to serve the most demanding of applications, with close to no intervention required.

For this application, two stages of drying were identified and supported using standard components including Direct Drive Fans and Process Heaters.

These were selected specifically for priorities of performance, efficiency, space footprint, reliability, and user-specific customisations. Global product certifications also allow various applications on an international level, including certification types CE, UL and CSA.

Stage 1 Drying

• Direct Drive Fan Model Secomak DD574

Combined with:

• Process Air Heater Model Secomak HT571 (2kW)

Plus for extraction:

• Direct Drive Fan Model DD513

Stage 2 Drying

• Direct Drive Fan Model Secomak DD669

Combined with:

• Process Air Heater Model Secomak HT632 (13.2kW)

Plus for extraction:

• Direct Drive Fan Model DD669

The Benefits

Leading performance combined with compact size was a key priority, ensuring the stationary product was treated quickly, evenly and effectively. A smaller space footprint also awarded the customer increased flexibility and extra room to allocate for other uses, such as future modifications to existing product designs.

Secomak’s latest Direct Drive Fans guarantee outstanding efficiency when mounting the motor directly to the fan unit, minimising friction and losses. Our fans are robust and well suited to the demands of continual printing. Built to the same stringent design standards as our gas rated products, they are engineered to the absolute highest standards, ensuring a long and reliable working life.

The Secomak Process Heaters range features rapid warm up and cool down phases to make sure that precise temperature control can be consistently maintained across an operating period, further increasing quality of product output and minimising wastage.

Simplifying where possible, our design incorporated the necessary adaptors and connectors and removed the customers obligation to source additional parts from suppliers, eliminating cost, additional assembly requirements and risk from external supply issues.

Secomak’s range of industrial fans and process heaters are compatible with applications anywhere in the world, including certification types CE, UL and CSA.

Please contact Secomak for more information about our Direct Drive Fans and Process Heaters.

Roxel Propulsion Systems design, develop, manufacture, and sell solid propulsion systems and related equipment for all types of rockets, including tactical and cruise missiles for air, sea and ground forces.

Employing 700 people worldwide, they are experts with the chemistry of energetic materials, interior ballistics, and mechanical fields, offering customers bespoke solutions for all elements of propulsion systems.

Roxel’s rocket motors are used in all types of missiles and rockets: air-to-air, ground-to-air, artillery, anti-ship, anti-tank, air-to ground, cruise missiles and guided bombs.

The Challenge

Roxel previously used a Secomak heater and fan to neutralise contaminants from explosives. This involved heating the waste in a special oven to 130 °C over a set time to a level deemed safe enough for disposal. They cannot recirculate air due to the contaminants re-entering the fan-heater combination, requiring the heater to be powerful and efficient.

Their old solution had insufficient airflow to keep pace with the increased volume of contaminated explosive waste that needed processing. The space inside their 10m³ oven was not being fully utilised as the fan-heater combination restricted how much they could heat up quickly. They needed a similar heat output to their existing solution, but in a faster timeframe.

The Solution

The Secomak Heat Pack 18 kW was selected for use by Roxel.

Supplying clean, dry, hot air, it was the perfect turnkey solution for Roxel to integrate into their existing controls and oven. Delivering consistent hot air efficiently is the main benefit of the Heat Pack, as well as coming pre-mounted on its base support with all adaptors included as necessary for a simple, turn-key installation. Optional braked castors and an adjustable height handle are available but were not fitted here.

The heater and blower items used in this Heat Pack are:

• 18 kW Output
• Model 648 Heater
• Model DD643 Direct Drive Fan

This solution can provide an impressive 300 °C of heat at the outlet, combined with 23 mbar of pressure and 2,200 cu.m/hr of volume, leaving plenty of headroom if they wanted to increase their volume or heat level.

The customer requested no controls on this unit, choosing to integrate with their existing system.

The Benefits

The Heat Pack provided reliable, hot air, consistently and on demand. This ensured that the same successful heat treatment was applied to every batch equally, with no dips in quality.

Secomak’s Direct Drive Fan technology ensures fantastic reliability, with zero maintenance required, eliminating downtime, and making sure production is never interrupted.

The DD643 Direct Drive Fan unit uses a modern IE3 motor, for excellent efficiency, particularly when used for a long period continuously.

The Heat Pack is also remarkably compact, pre-mounted to its base frame with all connectors already present, it produces airflow on a par with other solutions that are considerable larger.

Safe and simple to install, it fully complies with CE, EMC & Low Voltage Approvals, to install to any project with ease.

For more information on the Secomak Heat Pack, or any of our other Fans or Heaters, contact us today.

Marshalls Aerospace and Defence Group are a business and service provider to a range of customers in military and commercial markets in the air, land and sea domains.

The 1,700 employees work to design, manufacture, test and certify end-to-end solutions. Marshall’s advanced composite manufacturing techniques allow them to create anything from a bespoke designed one-off item to a line of customer-design products, using the latest composite materials.

Their specialist knowledge of smart materials allows them to lower cost, reduce weight, create superior aerodynamics, and optimise radio frequency (RF) performance.

The Challenge

The customer has several industrial ovens for composite curing. With often complex shapes and components of high value, the customer needed a solution that offered both a quick heating time and precision point accuracy when it comes to temperature control.

The customer has ovens of various shapes and sizes and rarely manufacture the same component back-to-back.

This meant that flexibility was key.

The system needed to scale easily, providing additional heat where the process demanded. It was also required to be mobile, making it easy for the user to move between ovens.

The Solution

Marshall’s project requirement for precision heating control, meant Secomak included our most sophisticated control system ever!

The heater and blower items used in this Heat Pack are:

• Model 648 Heater 18 kW Output
• Model DD643 Direct Drive Fan
• HMI Control Station (Human Machine Interface)
  • Includes blower inverter controls and solid-state relay heater controls

This solution can provide up to an impressive 300 °C of heat at the outlet, combined with up to 23 mbar of pressure and 2,200 m3/hr of volume.

The 18 kW heater was controlled with three separate 6 kW solid-state relays, together with a PID temperature control (Proportional, Integral and Derivative). This meant the output temperature was highly accurate to less than ± 1% and ensured superb energy efficiency.

The system allowed for up to 16 temperature probes, with the customer able to set high and low temperature thresholds for all 16 individual target zones. The alarms can be sent remotely to ensure the process never exceeds the set temperature.

Every control input was achieved through a simple-to-navigate HMI (Human Machine Interface) to minimise set up time and reduce the risk of operational error.

It was also designed with future expansion in mind, using a ‘master and slave’ operation. This functionality allows for up to three further 18 kW Heat Packs to be added and controlled by the single HMI.

The Benefits

Supplying clean, dry, hot air, the Heat Pack delivers an extremely efficient and consistent hot air solution.

Powerful and capable 300 °C of heat at the outlet, the Heat Pack is remarkably compact, producing airflow on a par with other much larger solutions.

The three 6 kW solid-state relays, combined with the PID temperature control delivered an incredibly accurate output temperature, within ± 1% to the desired level. This gives confidence to the user, even if the job if complex or requires a very particular temperature to succeed.

The 16 individual temperature zones increase this accuracy further, allowing more accurate control of high and low temperature thresholds. An alarm that alerts the user to the temperature moving outside of these parameters removes the risk of failure, even allowing alarms to be sent remotely to the user, such as if they are away from the site.

It was delivered pre-mounted on its base support with all adaptors included as necessary, creating a simple plug and play solution requiring only power to start operation, reducing setup time. Optional braked castors and an adjustable height handle were specified for this application, enabling the portability that was essential to meet the customer’s needs.

Secomak’s Direct Drive Fan technology ensures outstanding reliability, with zero maintenance required, eliminating downtime, and making sure production is never interrupted. The DD643 Direct Drive Fan unit uses a modern IE3 motor, for excellent efficiency, particularly when used for a long period continuously.

Safe and simple to install, the Heat Pack fully complies with CE, EMC & Low Voltage Approvals, to install to any project with ease.

For more information on the Secomak Heat Pack, or any of our other Fans or Heaters, contact us today.