How Hopper Heaters Assist in Liquid Filling Equipment

In industries such as food and beverage, chemicals, plastics and rubber, and oil and gas, controlling the temperature in hopper systems is crucial for managing fluid flow. This helps manage the flow of fluids.

The thickness of a fluid, known as viscosity, impacts how easily it moves. Fluids with high viscosity are thicker and flow more slowly, while those with low viscosity are thinner and flow more easily. Temperature affects viscosity, and heating a fluid can reduce its thickness, allowing it to flow better. Ensuring optimal fluid viscosity is essential for smooth and efficient operations in various industrial applications.

A notable challenge faced by an Original Equipment Manufacturer (OEM) specializing in liquid filling machines for diverse industries was addressing viscosity issues in one of their product lines. The end user required precise flow rates that the machine struggled to achieve because of cooling-induced viscosity increases. The issue was traced back to heat loss in the hopper assembly—an essential component used for holding and dispensing materials like waxes, oils, or viscous fluids.

Tempco’s solution involved integrating custom silicone rubber heaters into the hopper assembly. Engineers design these heaters to give steady and controlled surface heating. This is important for keeping the right viscosity without overheating the fluid. By applying heat to the exterior of the metal hopper, the internal fluid is gradually warmed, ensuring a stable flow rate.

Tailored Heating Solutions

Tempco provided two custom-designed heaters for this application:

1. Cylindrical Heater: This heater wraps around the top of the container, ensuring uniform heat distribution.
2. Cone-Shaped Heater: Specifically designed to encase the bottom funnel of the hopper, this heater helps maintain consistent heating throughout the container. 

Key Features:

• Surface Mount Thermostats: Each heater is independently controlled by thermostats with a temperature range of 70°-190°F, enabling precise temperature management.
• Easy Installation and Maintenance: Heaters are mounted with boot hooks and springs for straightforward installation and removal.
• User-Friendly Electrical Termination: Features a simple 120-volt plug for easy connection.
• Dual Wattage Options: 500 watts for the larger cone-shaped heater and 250 watts for the smaller cylindrical heater.
• UL Recognized Component: Ensures compliance with safety standards.

By using Tempco’s flexible heating solutions, the OEM solved the viscosity problems. They also met their customer’s flow rate needs efficiently. Tempco quickly designs and makes silicone rubber heaters, which helps improve industrial processes and boosts overall performance.

Impact of Temperature Control on Product Quality and Consistency

In industrial applications, precise temperature control affects viscosity. It also impacts the quality and consistency of the final product. Keeping fluids flowing smoothly is important for processes that require accurate measurements and consistency. For example:

• In Food and Beverage Manufacturing: Proper viscosity control helps in achieving consistent product texture and quality. Variations in viscosity can lead to inconsistent product texture or taste, affecting consumer satisfaction and regulatory compliance.
• In Chemicals and Plastics: Temperature control during processing can affect the chemical reactions and the physical properties of the final product. Accurate heating helps in achieving the desired chemical properties and avoiding defects like incomplete reactions or inconsistent polymerization.
• In Oil and Gas: For crude oil and other viscous fluids, heating is crucial for reducing viscosity and ensuring efficient pumping and transportation. Consistent temperature management helps in optimizing flow rates and reducing operational issues.

Using advanced temperature control systems, like precision heaters and real-time monitoring, can improve process efficiency. This helps maintain optimal viscosity, ensures product quality, and reduces waste. This leads to better overall performance and cost savings in industrial operations.

Tempco's flexible heaters are reliable for industries that require precise fluid handling and temperature control. They help keep the right viscosity and enhance process efficiency. Read more about the ins and outs of what you need to know about silicone heaters or talk to a heater expert today.