Thermal Coating

Reduces Temperature by 50% and Gas by 6.5% saving 44k per annum

Thermal Coating Reduces Temperature by 50% and Gas by 6.5% saving 44k per annum

EnerTherm Engineering has conducted an evaluation for a multinational food, snack and beverage corporation, Pepsico, to identify the most cost-effective thermal coating thickness to be sprayed over their process heater and fryer.

The main objective was to reduce surface temperature, heat losses and energy uses and to improve safety. Top coating is also used as a protective coating against acid/caustic and erosion.

EnerTherm successfully reduced the temperature with the thermal coating by 50%, gas by 6.5%, saving the equivalent of 44k per annum. Here’s how we did it…

The Process

We’d just like to point out that prior to the application of the thermal coating, the temperature was at 120 degrees Celsius.

To combat the problem, our sister company EnerTherm applied 800kg of EnoTherm T180-60 to the burner, fryer pan and fryer manifold pipework. After a three-week period, the waterborne coating was fully cured and in that time, the thermal conductivity of the coating decreased and the thermal performance of the coating peaked.

Numerous dry film thickness readings were taken over the burner fryer and on average the burner thermal coating thickness was 6.4mm and 12mm, for the fryer. With a weighted average per surface area, the overall thermal coating thickness achieved was 8.3mm. A chemically protective top coating was also applied to the thermal coating, too.

Overall, since the application of Thermal Coating, Pepsico have seen temperature reductions of 50-60% and distinct average drop in gas use of 23 m3/h.

Data analysis was carried out over an 8 week-period and was carried over the full range of delta T and solids, the two most significant primary variables that affect gas use. This gas-saving translated into 263 kW energy saved over the period analysed.

The theoretical calculation that only took into consideration production time (i.e. no startup, boil-out, or idle mode) was lower by 34 kW compared to the measured value.

The total accounted gas reduction in the period analysed amounted to 6.9%, in production and non-production. Another problem we’ve help solve.