Improving Yield in Hoppers with Heaters

In many food processing facilities, materials often get stuck in hoppers, leading to production inefficiencies. This is particularly common when handling viscous substances like liquids or fats that become less viscous upon heating. A common workaround has been to pour hot water over the hopper to facilitate material flow.

However, this method poses several challenges:

• Risk of burns from handling hot water

• Increased energy costs

• Messy cleanup due to water spillage

• Hygiene concerns in food processing environments

To address these issues, we recommend using silicone rubber heaters. By wrapping the entire hopper with a heater, materials can flow smoothly, reducing waste and improving production efficiency. Clients who have implemented this solution report enhanced safety, easier operations, and increased productivity.

Effectively Solving Hopper Yield Problems with Silicone Rubber Heaters

Materials sticking inside hoppers is a common issue in food factories, especially with high-viscosity or moist ingredients. This "yield loss" not only decreases production efficiency but also leads to significant annual losses due to wasted materials. It can also impact product quality and is a critical concern for many businesses.

The Limitations of Using Hot Water

While pouring hot water over hoppers is a widespread practice, it comes with drawbacks:

• Constant risk of burns

• High energy consumption

• Time-consuming cleanup

• Potential hygiene issues

Many have found this method to be a temporary fix rather than a long-term solution.

Benefits of Implementing Silicone Rubber Heaters

We offer custom-made silicone rubber heaters that fit snugly on the exterior of hoppers. These heaters provide uniform heating, ensuring materials flow smoothly.

Key features include:

• Ultra-thin design (1.5mm thick) saving space

• Customizable to fit various hopper shapes (conical, rectangular, etc.)

• Uniform heating with excellent thermal responsiveness

• Durable, withstanding continuous use up to 200°C

Clients have expressed satisfaction, noting improvements in safety, ease of operation, and productivity.

Improvements Observed After Heater Installation

In summary, the use of silicone rubber heaters leads to easier operations, enhanced safety, and improved production efficiency.

Features and Advantages of Silicone Rubber Heaters

Silicone rubber heaters are an excellent choice for resolving yield issues in food hoppers.

Flexible and Customizable Fit

With a slim 1.5mm profile, these heaters are made from silicone rubber combined with glass cloth, making them extremely flexible. This allows them to adhere perfectly to various hopper shapes, including curved surfaces and corners.

Tailored to Complex Shapes

Whether your hopper is circular, irregularly shaped, has holes, or curved surfaces, we can provide custom-made heaters to fit. Our strength lies in designing heaters that match the specific requirements of your facility.

The close fit ensures efficient heat transfer, providing a safer and smarter solution compared to traditional methods.

Quick Heating and Longevity

Silicone rubber heaters heat up rapidly, minimizing wait times in busy environments. They are designed to withstand continuous use up to 200°C, ensuring long-term, stable operation with reduced maintenance and running costs.

Versatility Across Industries

Beyond food hoppers, silicone rubber heaters are utilized in various industries, including chemical plants for heating reactors and in the pharmaceutical industry for precise temperature control.

Cost-Effective Alternative: Aluminum Foil Heaters

For those seeking a more economical option, aluminum foil heaters offer a lightweight and affordable solution, suitable when high heat output isn't required.

Easy Customization and Installation

Aluminum foil heaters can be designed to fit various shapes, including circular, perforated, and irregular types. They come with double-sided tape for straightforward installation without the need for additional tools or processing.

Note: Aluminum foil heaters have lower heat output and may not be suitable for high-temperature applications.

Waterproof Solution: TECHEATER

In environments requiring frequent cleaning or exposure to moisture, waterproof Tech Heaters are recommended.

All-Around Durability

Tech Heaters are waterproof and highly durable, resistant to heat, cold, steam, and weather conditions. They are ideal for high-temperature, humid production lines and areas with frequent cleaning.

Easy Installation

Designed as belts, Tech Heaters can be easily wrapped around pipes, pumps, and other curved surfaces without the need for tools.

Self-Regulating Temperature Control

Equipped with self-regulating features, these heaters adjust their heat output based on ambient temperatures, preventing overheating and potential damage. They can also be overlapped during installation.

Customizable Lengths

Tech Heaters can be manufactured up to 50 meters in length and can be cut to desired sizes using specialized kits and certified personnel.

Versatile Applications Beyond Hoppers

Tech Heaters are also effective for:

• Preventing pipe freezing in cold regions

• Maintaining appropriate temperatures for materials and products

• Preserving quality by preventing temperature drops between processes

They can be applied to various components, including pipes, valves, pumps, and tubes.

The disadvantages of techeaters are...

Tech Heaters have specific temperature ranges (approximately 60°C, 90°C, and 120°C). For applications requiring different temperature settings, custom-made silicone rubber heaters are recommended.

Summary

If you're unsure which heater best suits your needs, please feel free to consult with us. We will assess your environment and requirements to propose the most suitable heating solution, aiming to enhance your workplace together.