Heating, drying, evaporation
Equipment such as cookers, preheaters, dryers and evaporators, used for heating and drying of products have high energy consumption demands.
The energy efficiency of these maschines depends highly on heat and material flows. Optimization of these flows can result in extensive energy savings over time.
CORE’s adaptive process controllers for cooking, heating, drying and evaporation reduce temperature variations substantially, increase throughput and attain a stable, optimized process. Through this, our customers achieve savings in energy while increasing capacity.
Overcooking or undercooking material can have a substantial impact on energy consumption, loss of production, product quality and throughput, consequentially lowering revenue. CORE control allows real-time monitoring and automatic adjustment to key parameters decreasing large fluctuations in discharge temperature, thereby stabilizing the process to obtain the desired discharge temperature.
Discharge temperature from cooker stabilizes when the CORE controller is switched on.
Below, CORE’s advanced controllers for specific heating and drying applications are listed:
BATCH COOKER / CORE-BCOOK
The CORE-BCOOK controller is selecting the retention time for drying in a batch cooker based on measured moisture and temperature. The behavior of moisture and temperature during the drying phase highly depends on the composition of material in the batch cooker.
The development of the temperature and moisture gives an important indication of the drying process and by using these signals, CORE-BCOOK can control the batch cooking to ensure the best quality output. A significant amount of energy may be saved by reducing overcooking and increasing throughput. Quality variations are reduced as well. The CORE-BCOOK controller lower variations in residual moisture and allow to adjust residual moisture to the desired level. The stable discharge temperature also provides the basis for a good pressing, thus enabling a lower variation in the residual fat in the meal.
COAGULATOR / CORE-COAG
The CORE-COAG controller is regulating the flow through and the steam to a coagulator in order to automatically optimize throughput and stabilize the discharge temperature near a desired value.
The variations in discharge temperature are reduced, thereby avoiding periods with overcooking and periods of dropouts due to undercooking, also ensuring a more uniform quality downstream. A more stable exit temperature from the coagulator reduces the amount of energy required for heating the material. Excessive evaporation near the boiling point is avoided, but also the avoidance of too low temperatures saves energy downstream, because insufficiently coagulated material is badly separated and thus more moisture must be evaporated using more energy in subsequent processes.
CONTINUOUS COOKER / CORE-COOK
The CORE-COOK controller is regulating the various flows through and the steam to a continuous cooker. The CORE-COOK controller is designed to provide a stable discharge temperature thereby avoiding both too high and too low temperatures.
The advanced controller optimizes the throughput, keeping the cooker full and the discharge temperature at the desired level. A significant amount of energy may be saved by reducing overcooking and increasing throughput. Keeping the discharge temperature from the cooker at the right level and the throughput high, also reduces the quality variations, from meal quality to fat color. The CORE-COOK controller lowers the variation in residual moisture and allow to adjust residual moisture to the desired level. The stable discharge temperature also provides the basis for a good pressing, thus enabling a lower variation in the residual fat in the meal.
Download product leaflet here
DISK-DRYER / CORE-DDRY
The CORE-DDRY controller is regulating the various flows through and the steam to a disc-dryer. The CORE-DDRY controller is designed to provide a stable discharge temperature thereby avoiding both too high and too low temperatures.
The advanced controller optimizes the throughput, keeping the dryer full and the discharge temperature at the desired level. A significant amount of energy may be saved by reducing overdrying and increasing throughput. Keeping the discharge temperature from the dryer at the right level and the throughput high, also reduces the quality variations. The CORE-DDRY controller lowers the variation in residual moisture and allow to adjust residual moisture to the desired level. The stable discharge temperature also provides the basis for a good pressing, thus enabling a lower variation in the residual fat in the meal.
Download product leaflet here
EVAPORATORS / CORE-EVAPn
The CORE-EVAPn controller is regulating the flow through an n-stage evaporator system in order to maximize the evaporation within the given flow constraints, i.e. such that the evaporator system neither becomes a bottle-neck nor processes faster than necessary.
Optimal use of the evaporation system saves energy as well as production time.
Download product leaflet here
It is important to keep the discharge temperature at the right level in a fish cooker.
Using CORE technology (right), this is done automatically.
FISH COOKER / CORE-FCOOK
The CORE-FCOOK controller is regulating the flow through and the steam to a fish cooker in order to automatically optimize throughput and stabilize the discharge temperature near a desired value.
The variations in discharge temperature are reduced, thereby avoiding periods with overcooking and periods of dropouts due to undercooking, also ensuring a more uniform quality downstream. A more stable exit temperature from the fish cooker reduces the amount of energy required for heating the material. Excessive evaporation near the boiling point is avoided, but also the avoidance of too low temperatures saves energy downstream, because insufficiently coagulated material is badly separated and thus more moisture must be evaporated using more energy in subsequent processes.
Download product leaflet here
HOT-AIR DRYER / CORE-HADRY (CORE-FDRY)
The CORE-HADRY (CORE-FDRY) controller is regulating the material and hot air flow through a hot-air dryer. The controller uses information on temperatures and flows to regulate burner, recycle-air, infeed (if possible) and rotation speed.
Adding the advanced CORE-HADRY control help stabilizing temperatures and residual moisture and help improving capacity and energy efficiency.
PREHEATER / CORE-HEAT
The CORE-HEAT controller is regulating the flow through and the steam to a preheater in order to automatically optimize throughput and stabilize the discharge temperature near a desired value.
The variations in discharge temperature are reduced, thereby avoiding periods with overcooking and periods of dropouts due to undercooking, also ensuring a more uniform quality downstream. A more stable exit temperature from the preheater reduces the amount of energy required for heating the material. Excessive evaporation near the boiling point is avoided, but also the avoidance of too low temperatures saves energy downstream, because insufficiently coagulated material is badly separated and thus more moisture must be evaporated using more energy in subsequent processes.
Download product leaflet here
Top: To keep temperature in a preheater at the right level can be difficult.
Bottom: CORE’s preheater control provides the stability needed.
RENDER VESSEL / CORE-RVES
The CORE-RVES controller is regulating the flow through and the steam to a render vessel in order to automatically optimize the flow at a stable discharge temperature, saving energy and ensuring a more uniform quality downstream.
SPRAY-DRYER/ CORE-SDRY
This controller is regulating the material and hot air flow through a spray-dryer. The CORE controller uses information on air temperatures and flows to regulate the material flow as well as the air flow and temperature.
Adding the advanced CORE-SDRY control help stabilizing the residual moisture and help improving capacity and energy efficiency.
Download product leaflet here
"We chose CORE in optimising our heat treatment processes and saved 75 MWh weekly."
John Hindborg,
DAKA, Denmark
