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4th March 2025

Process Temperature Control

Process temperature control is a critical aspect of industrial operations, influencing everything from product quality and consistency to energy efficiency and equipment lifespan. In sectors such as food processing, pharmaceuticals, chemical manufacturing, and plastics, precise temperature management is essential to ensure compliance with regulatory standards and to maintain optimal production efficiency.

At Newsome, we specialise in designing and delivering bespoke process cooling solutions that cater to the specific requirements of each industry. Our expertise covers everything from temperature control units (TCUs) , chillers and boilers to advanced monitoring systems and energy-efficient heat recovery technologies.

What is Process Temperature Control?

Process temperature control involves the regulation of temperature during manufacturing processes to maintain product quality, ensure safety, and optimise efficiency. It typically includes heating, cooling, or maintaining specific temperature ranges for materials and equipment. Inconsistent temperature control can lead to product defects, equipment failures, and increased energy consumption.

For example, in the food and beverage industry, precise temperature control is essential during pasteurisation, fermentation, and storage to prevent contamination and ensure product consistency. Similarly, in pharmaceutical manufacturing, temperature deviations can compromise the stability and efficacy of drugs. The effectiveness of process temperature control depends on selecting the right combination of heating and cooling equipment, sensors, controllers, and monitoring systems to regulate temperature accurately and efficiently.

Key Components of Process Temperature Control Systems

Effective process temperature control systems typically consist of the following key components:

  1. Temperature Control Units (TCUs):

TCUs are designed to regulate the temperature of processes by circulating heated or cooled fluid through equipment such as moulds, tanks, or reactors. These units include a heating element, a cooling circuit, and a pump to circulate the fluid, ensuring precise temperature control.

Common types of TCUs include:

Water-based TCUs: Ideal for applications requiring moderate temperatures (up to 90°C).

Oil-based TCUs: Suitable for high-temperature processes (up to 350°C).

Hybrid TCUs: Offer both water and oil circuits for versatile temperature management.

  1. Industrial Chillers:

Chillers remove excess heat generated during manufacturing processes by circulating coolant through a closed-loop system. They are essential in industries such as plastics, metalworking, and food processing, where consistent cooling is required to prevent overheating and maintain product quality.

Chillers are available in various configurations:

  1. Heat Exchangers:

Heat exchangers facilitate the transfer of heat between two or more fluids without direct contact, making them essential for maintaining temperature stability in processes involving chemical reactions, distillation, and refrigeration.

  1. Sensors and Controllers:

Accurate temperature measurement is critical for process control. Thermocouples, resistance temperature detectors (RTDs), and infrared sensors are commonly used to monitor temperature. Controllers, such as PID (Proportional-Integral-Derivative) controllers, interpret sensor data to adjust heating or cooling systems in real time.

  1. Monitoring and Control Systems:

Advanced SCADA (Supervisory Control and Data Acquisition) systems and PLC (Programmable Logic Controllers) provide real-time monitoring and control of temperature parameters. These systems enable remote access, data logging, and integration with other process control systems for comprehensive temperature management.

Challenges in Process Temperature Control

Maintaining precise temperature control presents several challenges, particularly in industries with dynamic operational conditions. Key challenges include:

  1. Heat Load Variability:

Fluctuations in heat load due to changes in production speed, raw material temperature, or environmental conditions can complicate temperature regulation. Effective process temperature control systems must adapt quickly to these changes to maintain stability.

  1. Energy Efficiency:

Temperature control processes, particularly those involving high-temperature heating or intensive cooling, can significantly impact energy costs. Integrating energy-efficient components and heat recovery systems can help mitigate these costs.

  1. Compliance and Safety:

Industries such as pharmaceuticals and food processing must comply with strict regulatory standards for temperature control to prevent contamination and ensure product safety. Failure to maintain compliant temperature conditions can result in product recalls and legal liabilities.

  1. Integration with Existing Systems:

For facilities with existing temperature control systems, integrating new solutions without disrupting production can be challenging. Modular and scalable control systems can help streamline integration and reduce downtime.

Energy Efficiency in Process Temperature Control

Energy efficiency is a critical consideration in process temperature control, particularly for industries with high cooling and heating demands. Energy-efficient solutions can significantly reduce operational costs while minimising environmental impact.

Heat Recovery Systems:

Heat recovery systems capture waste heat from manufacturing processes and repurpose it for space heating, pre-heating water, or other thermal applications. This approach not only improves energy efficiency but also reduces the load on primary heating systems.

Variable Speed Drives (VSDs):

Integrating VSDs into chillers and pumps allows dynamic adjustment of speed and power based on real-time demand, reducing energy consumption during low-load periods.

Smart Control Systems:

Advanced control systems equipped with predictive algorithms can optimise temperature control settings based on historical data and current conditions, ensuring efficient operation without compromising process requirements.

Benefits of Effective Process Temperature Control

Implementing a well-designed process temperature control system offers multiple benefits:

  1. Enhanced Product Quality:

Consistent temperature control prevents defects, contamination, and inconsistencies in products, ensuring compliance with quality standards.

  1. Increased Operational Efficiency:

Efficient temperature management reduces downtime caused by equipment overheating and optimises production throughput.

  1. Cost Reduction:

Energy-efficient control systems and waste heat recovery significantly reduce energy costs associated with heating and cooling processes.

  1. Regulatory Compliance:

Accurate temperature control ensures compliance with HACCP, BRC, GMP, and other industry-specific standards, mitigating risks of fines and recalls.

Why Choose Newsome for Process Temperature Control?

Newsome offers a comprehensive range of process temperature control solutions, from temperature control units and industrial chillers to heat recovery systems and advanced monitoring solutions. Our approach is based on:

  • Tailored Solutions: Designing systems that match your specific operational requirements.
  • Energy Efficiency: Implementing technologies that reduce energy consumption without compromising performance.
  • End-to-End Service: Providing design, installation, commissioning, and maintenance services to ensure optimal performance.
  • 24/7 Technical Support: Offering round-the-clock support to address any operational challenges.

Effective process temperature control is essential for maintaining product quality, ensuring regulatory compliance, and optimising energy efficiency in industrial environments. By investing in advanced temperature control systems that integrate energy-efficient technologies, real-time monitoring, and predictive analytics, businesses can significantly enhance their operational capabilities.

With our expertise in designing and delivering bespoke process temperature control solutions, Newsome is committed to helping industries achieve precision, efficiency, and sustainability in their temperature management systems. Contact us today to learn more about our tailored solutions and how they can enhance your operations

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