Steam Boilers in Dairy Industry: Its Use and Important Factors
Steam Boilers play a major part in any processing industry and an unarguable fact is that they are the backbone of the dairy and milk processing industries and require to be; highly efficient, resilient, and preferably compact for seamless operations. Boilers in the dairy industries mainly perform the processes of milk pasteurization and Ultra Heat Temperature (UHT) to ensure that the milk is safe for consumption and free from harmful bacteria for optimal shelf life. The milk processing plants utilize steam for processing and pasteurizing raw milk and dairy products under heat treatment. It leads to the process and production of various dairy products such as milk powder, yogurt, cheese, condensed milk, skimmed milk, butter, ghee, and cream.
India is the world’s largest dairy industry producing over 187 million tons of milk. It is therefore natural to conclude that India is the largest milk producer and consumer in the world. Milk and milk products have an imperative place in Indian cuisine. The North Indian population largely resorts to milk processed items such as cheese, ghee, and cottage cheese/paneer for their cooking, while the South Indian population uses milk and yogurt in their traditional dishes. Milk is a staple in the religious practices and ceremonies in India and an essential ingredient for Ayurveda medicinal purposes.
Use of Steam Boiler in Dairy Industries:
Boiler for the milk industry is crucial to ensure that the raw milk does not contain any harmful bacteria such as pathogens. Steam boilers are used for processing raw milk under high temperatures to ensure that it is safe for usage and other milk processing operations.
Raw milk processing takes place through the following procedures:
Pasteurization:
Pasteurization is a process where the temperature of the raw milk is increased to around 212 degrees Fahrenheit to assure that all the harmful bacteria that may cause harm to the milk are neutralized.
Ultra Heat Temperature (UHT):
Ultra Heat Temperature or UHT is the process that increases the milk temperature and sterilizes it over 275 degrees Fahrenheit for around 5 seconds. The process ascertains the complete removal of the bacterial spores.
Apart from these, boiler for milk dairy generate steam for the purpose of sterilizing the boiler and equipment involved during the processing operation and heating the dairy plant itself to ensure that there are not any bacteria present in the processing operation.
Factors to Consider while selecting Boiler for Milk Industry and Milk Processing Operation:
Although demands may slightly vary in different processing plants, some of the important and unavoidable factors to keep in mind while choosing a boiler for milk dairy industry are:
Reliable and Resilient to handle fluctuating load:
Most milk processing plants operate for long hours throughout the day. Therefore, the steam boilers must be reliable and resilient enough for managing the on-off operations in the processing units easily and swiftly. Boiler for milk dairy must be highly efficient as the dairy industry demands and operates with precision in steam and temperature.
Compact in design and size:
Although it may not be an essential requirement for the dairy industry, it is advisable to opt for compact steam boilers. It takes less footprint and leaves room for other equipment that may facilitate the processing operation further.
Sustainable and Environment Friendly:
Dairy industries use boilers on long cycles that means that they function for a longer duration. It leads to a high level of pollution that causes harm to the climate. It is, therefore, important that the boilers are environmentally friendly and contribute towards sustainable development.
Cost-effective and Economical:
As already mentioned, boilers are operated with high frequency in milk processing plants. Considering the high scale consumption of milk globally, steam boilers are required to be economical and cost-effective to produce and supply milk and milk products in the market at affordable prices without bringing loss in the processing plant itself. Because of these reasons, it is wise to select boilers that are cost-effective and work with different fuels as per the availability.
Highly Efficient:
Needless to say, a boiler for milk dairy should be highly efficient and durable to ensure the smooth functioning and maintenance of the dairy industries.
Rakhoh Boilers, with more than 38 years of experience, manufactures and installs highly efficient and long-lasting steam boilers in the dairy industries. Along with that, Rakhoh’s skillful and dedicated team works tirelessly to provide the best maintenance service and upgrades in the boiler for the milk industry.
As of 2020, India is the most self-sufficient milk producer in the world, with about 4.2 % of India’s Gross Domestic Product (GDP) falling under the dairy industry along with export to countries such as Bhutan, Turkey, United Arab Emirates, and Egypt at the value of US$186.71 million or Rs.1341.03 Crore.
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Steam Boilers for Tea Industry | How Steam is Used for Processing Tea?
Tea is a staple beverage all over the world, especially in India. The refreshing drink is preferred and loved by many in various forms for centuries. Therefore, processing tea leaves needs care and precision to obtain perfect and aromatic brewed tea for consumers. Steam Boilers are highly important in the tea industry as steam plays a crucial role in its various process operations.
In earlier years, tea was also utilized for medicinal purposes. It is consumed in different ways; fermented with ‘black tea,’ non-fermented with ‘green tea’ and semi-fermented with ‘oolong tea’, which is mainly preferred in China and Japan. Fermentation is a vital stage in tea processing as it ensures the quality, strength, aroma, and color of the tea produced.
There are around 34 countries globally that produce tea extensively. Countries like India, Sri Lanka, and China are leading tea producers in Asia, whereas Kenya, Rwanda, Tanzania, Uganda, and Malawi are the major African countries known for tea cultivation.
Stages in Tea Processing:
The tea process consists of drying the tea leaves collected from the tea plant named Camellia Sinensis. The leaves are processed into dried tea leaves. It is imperative to control the moisture content and temperature of the tea leaves, failing which, would result in the growth of fungi on the leaves that would make it unsuitable for consumption. While the tea leaves are processed into the brewing tea, it requires steam at a determined temperature. Among the various processes carried in the tea industry, two of the most important ones are the withering and drying process. Let us have a look to know about both the processes in detail.
Withering:
Tea leaves, when brought from plantations, include moisture content in it that has to be removed. The withering process eliminates partial moisture content from the leaves before it is transferred for subsequent operations. Withering is the most extensive process operation in the tea industry as it requires approximately 50% of the thermal energy of steam boilers and 40% electricity of the process plant.
Drying:
Tea drying is the second process in tea factories after withering. The process requires around 40% of the thermal energy from the steam boiler and 20% of the factory’s electricity. Once the fermentation process is carried, the tea leaves are subsequently transferred, for the drying process in the drying room. Over there, the fermented leaves are placed on the trays of a dryer. It is heated at a temperature ranging between 200°F and 220°F to eliminate the remaining moisture content from the leaves.
Steam Boilers in Tea Factories:
Steam boilers are crucial to successfully accomplish the withering and drying operation in the tea process plants as it requires an abundant amount of steam. The withering and drying process alone requires 90% of the tea factory’s total heat, and therefore, the steam boilers installed at the processing plant must be highly efficient and durable. Since both the processes consume a high amount of energy, boiler manufacturers suggest a few methods that assist in reducing the energy consumption such as:
- Fan and warm air should be utilized at minimal levels.
- Assess and maintain fan blade positioning
- Ensure that heat exchangers are clean and well-maintained
- Spread tea leaves uniformly to minimize air resistance
- Place air dampeners parallel to the airflow
- Regularly check and maintain fans and motors from boiler manufacturers
- Make sure that the steam pipes are properly insulated
- Clean the equipment and fans after operations
- Place air dampeners at an appropriate angle between the wet end and the dry end of the dryer.
- Control and Monitor the air intake
- Do not open the flow control dampeners unnecessarily
- Note the temperature of tea leaves placed in dryers to administer only the required amount of steam
- Ensure that all the machinery are functioning properly under the guidance of the boiler manufacturer
- Regular servicing and maintenance of steam boilers from the boiler manufacturer
Why Choose Rakhoh Boilers for the Tea Industry?
Rakhoh is a trusted brand as a boiler manufacturer since its inception in 1983. We have always strived and successfully manufactured industrial steam boilers of premium quality that are durable and safe. Catering to more than 20 industries, we understand the needs and demands of different industries and provide our best services with steam boilers and thermal solutions. We have installed steam boilers in various tea factories in India and abroad with our Bi-Drum model being the preferred choice among our tea industry clients.
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Steam Boiler in Rubber Industries and the Process of Rubber Manufacturing
Since boilers are a crucial part of the processing industry, manufacturers strive to supply the industry with boilers that are efficient, cost-effective, and long-lasting. The rubber industry requires highly efficient and sturdy boilers to ensure the smooth processing of raw rubber into the final product used extensively for many purposes.
Rubber is utilized in many industries and fields, serving different purposes. The most important among them are rubber tyres in vehicles that are responsible for the balance and carrying the weight of the concerned vehicle. Therefore, the rubber for tyres must be of supreme and sturdy quality. Apart from tyres, it is used for machinery, medical, construction, mining, electronic devices, and household equipment.
Rubber is mainly of two forms namely, Natural Rubber and Synthetic Rubber. With the processing operations, it is manufactured into rubber products.
Difference between Natural Rubber and Synthetic Rubber:
Natural Rubber is latex that is a sap-type milky material found in more than 2,500 plants. Latex for commercial use is found in a tropical tree named ‘Hevea brasiliensis’ and contains polyisoprene polymer. Whereas rubber is a specific form of polymer that can flex and stretch called ‘elastomer’
However, over 70% of the rubber used nowadays is synthetic rubber. Synthetic rubber is developed through the process of polymerization, wherein the molecules are linked together in long chains. The development of synthetic rubber has continued and advanced through the years.
Manufacturing of Rubber with Steam Boilers:
Rubber arrives in processing plants in either natural or synthetic form and undergoes four processes to complete its manufacturing. These four processes are Compounding, Mixing, Shaping, and Vulcanizing. It is noteworthy that the compounding process depends on the intended product of the rubber.
Compounding:
Compounding is the process wherein, chemicals and additives are included to modify the rubber, depending on the final product. The chemicals added during the compounding process react with the rubber later in the vulcanization process to stabilize its polymers. Other additives used during the compounding process are Reinforcing fillers, Non-Reinforcing fillers, Color pigments, antioxidants, ozone-resistant chemicals, softening oils, and others.
Carbon black acquired from soot is one of the majorly used reinforcing fillers. It increases the strength and improves the resistance to tearing and ultraviolet depreciation of rubber. Therefore, most of the rubber products are in black.
Mixing:
It is important that the mixing of the additives is accomplished accurately in a rubber, which is difficult considering the high viscosity found in rubbers. Because of this, an increase in temperature is required. But, raising the temperature of rubber to 200 degrees Fahrenheit may cause premature vulcanization. To avoid such situations, mixing is achieved in two stages, in which carbon black is added first to the rubber and then followed by other chemicals and additives once the rubber gets cooled in the second stage.
Shaping:
Shaping of the rubber can occur in 4 different ways– calendering, casting, coating, and extrusion. The calendering process takes place by passing the rubber through a set of rolls to acquire the desired thickness. Casting occurs by dipping or casting a negative mold in a rubber bath and later dried with cross-linking. The coating is applying a coat of rubber to other materials such as tents, raincoats, etc. The extrusion process occurs by forcing plastic rubber through numerous screw extruders.
Vulcanization:
Vulcanization (also known as curing) is the final process that completes the manufacturing of rubber. Cross-linking in rubber begins from the mixing process but at an initial level. Vulcanization takes place after the process of shaping; which heats the rubber through hot steam of about 200 degrees Celsius that resultantly increases the vulcanization rate. In steam vulcanization, the processing operation takes place by direct contact of steam with the rubber. It is, therefore, essential to conduct regular treatment of the steam as the direct contact leads to its impurity. Because steam has a high vulcanization capacity, boilers must be maintained properly as per the guidance of the steam boiler manufacturer to ensure smooth running.
Rakhoh is one of the leading names in steam boiler manufacturers. We have manufactured and installed highly efficient and sturdy boilers for many manufacturing industries by understanding their respective demands and requirements.
In the case of rubber manufacturing industries, it is prudent to ensure that the steam boiler used is:
Adaptable to the Fluctuating Demand: The steam demand in a rubber processing plant may increase or decrease various times, depending on the product. Fluctuation is one of the most faced difficulties in a rubber processing plant.
Efficient in Energy: One of the trials faced by rubber processing plants is to reduce the fuel consumption and energy output of the boiler. A boiler that generates higher steam output and demands minimum energy is ideal for rubber manufacturing.
Reduced Emission: Steam boilers that reduce greenhouse emissions and comply with sustainability are suitable for any processing units to preserve nature.
Learn more about Rakhoh’s Boilers and Services on http://www.rakhoh.com
FAQ:
1. Which kinds of Boilers are suitable in the Rubber Industry?
Nowadays, Water Tube Boilers are preferred over Fire Tube Boilers as they help in saving fuel and resources and ensuring longer life of boilers
2. How to know that the selected steam boiler would reduce greenhouse emissions?
Ask your steam boiler manufacturer for a product rated for low CO2 emissions.
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Use and Types of Steam Boilers in Pharmaceutical Industry
Pharmaceutical is one of the important and rapidly progressing sectors worldwide. The immense contribution of scientists in the research and development of medicines is advancing towards a better quality of life globally. India’s pharmaceutical sector covers over 50% of global vaccination demand. India ranks second in the global pharmaceutical workforce and contribution, with the USA being the largest importer of Indian pharmacy among 200 countries.
Pharmaceutical manufacturers utilize different equipment at different stages of drug production. The manufacturing process in pharmaceuticals consists of several stages like milling, blending, granulation, coating, drying, encapsulation, tablet pressing, and so on. To accomplish this, pharmaceutical firms require instruments such as X-ray inspection systems, capsule filling machines, tablet punching machines, and undoubtedly, boilers.
Process of Pharmaceutical Manufacturing:
The pharmaceutical process begins with milling or decreasing the component size to the requirement of the manufactured drug and continuing with the process of combining the non-active ingredient with the active pharmaceutical ingredients to procure a solid dosage.
After milling comes the granulation process that is divided into two forms: Wet Granulation and Dry Granulation. It is a reverse of milling as it blends all the small drug particles into one large particle. This large granule consists of the ingredients in their precise amount, enhancing its compression ability for tablet formation.
Hot-melt extrusion is performed with solid oral drugs by processing it with less solubility through heat and pressure. The manufactured drug is later compressed into tablets and capsules.
Steam Boilers in Pharmaceutical Sector:
Efficient and reliable boilers are the backbone of the pharmaceutical industry. Steam boilers are crucial in the drug manufacturing industries for sterilizing, purifying and drying. Steam boilers are essential to ensure precision in the compiling of the components in the manufactured drug. Clean Steam or Pure Steam is of vital importance for the superior quality of the drugs produced.
Clean steam is produced from uncontaminated water that is free of additives such as amines. It is mainly because the disinfection and sterilization process must be absent of any form of contamination that may hamper the quality of the manufactured product.
Apart from these, clean steam is required for a sterile surrounding to encourage the growth of yeasts or cells. It is also required for the processing of eye or ear drop solutions.
Pharmaceutical industries generally use Solid Fuel Boilers, Oil fired Boilers, and Multi Fuel Boilers for manufacturing depending on their requirements.
Solid Fuel Boilers: Solid fuel steam boilers are efficient and economical compared to other types of boilers and burn on fuel like wood, coal, wooden chips, briquettes, etc.
Solid fuel boilers are beneficial because of their low operating costs, range of fuel choice, and optimum efficiency. Solid fuel boilers are used for manufacturing generic medicines, IV fluids, capsule covering, and so on.
Oil fired Boilers: Oil fired boilers are an ideal choice where there is low availability of Natural Gas and Solid Fuels. Oil fired boilers are highly effective with optimal combustion and work with fuels like Light Diesel Oil, High-Speed Diesel, Furnace Oil, Low Sulphur Heavy Stock, and Industrial Diesel Oil.
In drug manufacturing, it is mainly utilized for sterilization, disinfection, and mixing of components.
Multi fuel Boilers: As the name suggests, multi fuel boilers work with various types of fuels. Multi fuel boilers are efficient and reliable, and mainly used in manufacturing products like tablets, medicinal syrups, injections, and ointments.
Importance of Safe and Reliable Boilers:
Precision and Safety is the key to successful pharmaceutical manufacturing. Although the pharmacy sector plays an important role, there can be no doubt that it has its share of challenges in manufacturing. Hot liquids, Hot surfaces, Steam, Constricted Workspace, High noise levels, and an Overly heated work area are some of the difficulties faced by workers in the manufacturing units. Working in such an environment may cause harm to skin, eyes, ears, kidneys, and lungs due to suffocation, lack of oxygen, and exposure to a high level of noise and heat. Therefore, it is essential to install and use instruments of superior quality and reliability.
Conclusion:
India’s medical industry is growing by 15.2% yearly and may reach $25 million by 2025. Government plans to allocate $1.3 billion (Rs. 1 Lakh Crore) to encourage and increase domestic pharmaceutical manufacturing by 2023.
Rakhoh Steam Boilers in Pharmaceutical Sector:
Rakhoh has provided efficient and reliable boilers in the pharmaceutical sector. We manufacture and install solid fuel boilers such as Combo X, Optipac, and Solid Fuel Bi-Drum. Our oil fired boiler Oilpac and Multi fuel range of boilers include Membrane X and Thermic Fluid Heater.
- Some of our clients from the pharmaceutical sector include
- Hindustan Antibiotics Limited.
- Makson Nutrition India Private Limited
- Marksans Pharma Limited
- Porus Laboratories Private Limited
- Natco Pharma Limited
- Shashun Pharma
- Nutra Plus Products India Limited and many others
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Steam Boiler Efficiency: Factors and Ways to Increase Boiler Efficiency
Steam boilers, as we know, play an indispensable role in any field of industry. To run and handle any industry or processing plant is not everyone’s cup of tea. Various factors are determined and decided upon to ensure that the concerned industries are running smoothly and effectively.
Steam boiler manufacturers provide their efficient and reliable boilers to their clients but are they truly as efficient as they claim? Why is efficiency an imperative factor in choosing a boiler? And most importantly, how can we measure and determine the efficiency of the boiler? Read on to know the details to direct your decision in finding an efficient boiler.
Steam boilers are an important tool in various industries and an unarguable fact is that the initial investment in a boiler is a mere fraction of the total annual investment on its fuels. Hence it is prudent to ensure that the boiler delivers the efficiency as warranted by the steam boiler manufacturer.
Efficiency in Steam Boiler:
In a nutshell, boiler efficiency is the difference between energy input and energy output that can be calculated and indicated with percentage. The boiler efficiency depends on several factors particularly, Combustion efficiency and Thermal efficiency. It is also termed ‘fuel-to-steam efficiency’ that can assist in assessing the future fuel costs and the estimated lifespan of the boiler.
Methods to Ascertain Boiler Efficiency:
There are several ways to determine steam boiler efficiency. Different methods calculate different factors that eventually lead to boiler efficiency. In calculating boiler efficiency, a ratio varying from the expected ratio indicates the need to modify the operation process or get in touch with the steam boiler manufacturer for their superior knowledge and assistance.
Combustion Efficiency:
Combustion efficiency helps to determine the burner’s capability to burn fuels effectively and assess the unburnt fuel and excess air present in depleting. A boiler is considered efficient if both the unburnt fuel and excess air are at lower levels.
When the boiler efficiency deviates from the desired ratio, it is advisable to assess flue gas oxygen and stack temperature because they are important factors affecting Combustion efficiency. The ideal range of Combustion efficiency of steam boilers is between 75% and 89%
Thermal Efficiency:
Thermal efficiency assesses the efficacy of the heat exchanger that enables the transferring of the heat energy to the water or steam. With setting up of soot or water scaling, poor condition of the heat exchanging surface within the boiler results in affecting the thermal efficiency negatively, which, in turn, lowers the overall efficiency of the steam boiler.
Fuel-to-Steam Efficiency or Fuel-to-Water Efficiency:
Fuel-to-Steam efficiency or Fuel-to-Water efficiency (also referred to as ‘Boiler efficiency’ or even Thermal Efficiency) determines the overall efficiency of the boiler. It differs slightly from thermal efficiency by calculating not only the effectiveness of the heat exchanger but also the radiation and convection losses.
The optimum score for fuel-to-steam efficiency ranges from 80% to 85% and acts as the indicator for the overall boiler efficiency.
Factors Affecting the Boiler Efficiency:
Many factors contribute to the efficient performance of a boiler. It is imperative to understand them while assessing the boiler efficiency and take appropriate actions or contacting the steam boiler manufacturer in due course to ensure better efficiency and longer lifespan of the boilers.
Some of the factors that affect the efficiency of steam boilers are:
Flue Gas Temperature:
Flue gas temperature refers to the temperature of the combustion gases when they exit the boiler. In simple words, high flue gas temperature indicates that the heat is being lost during the process. It means that the efficiency of the boiler is below the desired range.
Stack Losses:
Stack temperature is an ideal indicator of boiler efficiency. The stack temperature refers to the temperature of the combustion gas (both dry flue gas and water vapor) exiting the boiler. It demonstrates the heat which did not transfer from the fuel to the water or steam, thus indicating the effectiveness of the heat exchanger. It displays the fuel-to-steam efficiency of the boiler
Radiation and Convection Losses:
Radiation and Convection losses in a steam boiler are inevitable as they are the heat losses that radiate from the boiler vessel. The amount of radiation and convection losses varies due to the factors such as boiler size, boiler type, operating pressure, and air velocity across the boiler. Such factors have an undeniable influence on radiation and convection loss. But ultimately, every boiler faces some type of heat loss that radiates in the boiler vessel.
Ambient Air Temperature:
Ambient air temperature considerably affects the efficiency of boilers. The temperature of the combustion air emerging in the boiler is known as ambient air. To understand this better, a 40 degrees Fahrenheit can vary the boiler efficiency by 1% or more that may have a far-reaching influence on the operations of the steam boilers.
Turndown:
Turndown indicates the capability of the boiler to attain a wide range of output (low to high). Therefore, a higher turndown implies a wide range of output ability of the boiler. Boilers achieving a high turndown ratio can supply steam at lower rates without restarting or shutting down. It shows that when demand load fluctuates, higher turndown can facilitate efficiency improvements.
Fuel Specification:
Fuel specification plays a key role in determining the efficiency of the boiler. Let us consider the example of gaseous fuels as they contain high hydrogen content resulting in high water vapor during combustion. It leads to high vapor loss and low efficiency. That is the reason for oil-fired boilers offering higher efficiency as compared to boilers burning on gaseous fuels.
Tips to Increase Boiler Efficiency:
One has to calculate and determine the factors that are hindering the higher efficiency of boilers. There are several ways to improve the efficiency of the boiler by taking some appropriate and well-timed action:
- Installing a Flue Gas Economizer to assist in recovering the surplus heat
- Improving Boiler Insulation to reduce the radiation and convection losses
- Recovering heat from boiler blowdown
- Cleaning and regular servicing of boiler internals
- Retrofit or Upgrade Boiler Burners or Components
- Adopt and Practice Preventive Maintenance
- Contact Steam Boiler Manufacturer for regular service check
Rakhoh Boilers are a leading and trustworthy steam boiler manufacturer committed to designing, manufacturing, and installing highly efficient and reliable boilers for clients. Our expert and dedicated staff manufacture and install boilers along with providing excellent and cost-effective retrofit and upgrading services to ensure long-lasting, highly efficient, and durable steam boilers.
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