🏭 Thermokrupp Engineers
⚙️ 15+ Years Experience
Not just a product—a solution. In March 2024, Thermokrupp Boilers completed the design, fabrication, and commissioning of a custom 600°C indirect-fired Hot Air Generator for a major breakfast cereal manufacturer in Punjab. This case study details the engineering challenges, customizations, and performance results. If you are evaluating Hot Air Generator manufacturers for food processing applications, this is a real-world blueprint of what’s possible.
🥣 The Challenge: Contamination-Free Drying at 600°C
Our client, a leading breakfast cereal and instant food manufacturer in Ludhiana, Punjab, was facing a critical bottleneck. Their existing steam-based system could only achieve 180°C, which was insufficient for a new high-protein cereal line requiring direct, moisture-free hot air at 550°C–600°C. Furthermore, any contamination from combustion gases was strictly prohibited due to food safety standards (FSSC 22000).
❌ Steam System Limitations
- Max temperature: 180°C
- High moisture content
- Slow response time
- Scale buildup in coils
✅ Required HAG Specifications
- Output: 550°C – 600°C
- 100% clean, indirect air
- Fuel: Natural Gas (backup LPG)
- Airflow: 12,000 CMH
⚙️ The Engineering Solution: Custom TK-HAG-600
Thermokrupp’s design team proposed our TK-HAG-600 model, but with three critical customizations not available from standard manufacturers:
1️⃣ SS316L Heat Exchanger
Standard HAGs use MS or SS304. For 600°C continuous operation and corrosion resistance against food acids, we upgraded to SS316L titanium-stabilized steel. 100% contamination-free.
2️⃣ PLC + HMI Control Panel
Custom Siemens PLC with recipe management. The client can store 5 temperature profiles for different cereals. PID control maintains ±3°C accuracy.
3️⃣ Hybrid Burner System
Dual-fuel (NG + LPG) with automatic changeover. If gas pressure drops, the system switches to LPG in < 2 seconds. Zero production interruption.
4️⃣ Space-Saving Skid Mount
Fully assembled on a single structural skid. Plug-and-play installation completed in 3 days vs. 2 weeks for field-erected units.
📅 Manufacturing Timeline: 4 Weeks from PO to Dispatch
One question we always hear: “How quickly can a custom Hot Air Generator be manufactured?” Here is the actual project timeline from this order:
| Week | Activity | Status |
|---|---|---|
| Week 1 | Order confirmation, technical specification sign-off, material procurement (SS316L sheets, burner, fan) | ✅ Completed |
| Week 2 | Shell fabrication, tube cutting, heat exchanger assembly | ✅ Completed |
| Week 3 | Welding, NDT testing, refractory lining, control panel wiring | ✅ Completed |
| Week 4 | Factory trial, IBR inspection, painting, dispatch to Punjab | ✅ Completed |
📌 Key Takeaway: Custom manufacturing does not always mean long lead times. With in-house control over fabrication, Thermokrupp delivered a custom 600°C HAG in 28 days – faster than many suppliers deliver standard units.
🔧 Installation & Commissioning: 3 Days On-Site
The skid-mounted design reduced installation complexity significantly:
- Day 1: Unit placed on foundation, ducting connected, flue stack erected.
- Day 2: Gas line connection, electrical termination, sensor calibration.
- Day 3: Cold commissioning, hot trial at 600°C, operator training.
Client feedback: “We expected at least 10 days of disruption. Thermokrupp’s team completed everything in 3 days without affecting our existing production line.”
📊 Performance Results
✅ ±2°C temperature uniformity
✅ 22% fuel savings vs. old steam boiler
✅ Oxygen < 2% in flue gas
✅ 0 ppm contamination in product
📋 Buyer’s Guide: 5 Questions to Ask Your Hot Air Generator Manufacturer
Based on this project, here are the 5 most critical questions procurement and engineering teams should ask before placing an order:
1️⃣ “What is the material of the heat exchanger tubes?”
Many manufacturers quote MS and later suggest SS at huge premiums. Specify SS316L for >450°C or corrosive environments in the quotation stage.
2️⃣ “Do you manufacture the control panel in-house?”
Third-party panels often cause integration delays. Thermokrupp designs and assembles panels in-house, ensuring single-point responsibility.
3️⃣ “What is the actual thermal efficiency at your quoted temperature?”
We guarantee 88% ±2% at 600°C for indirect-fired models. Ask for test certificates.
4️⃣ “Who holds the IBR certification – you or your subcontractor?”
Thermokrupp is an IBR-approved manufacturer (Certificate available on request). We do not third-party certify.
5️⃣ “What is the lead time for spare parts?”
We stock critical spares for all models dispatched in the last 7 years. 24-hour dispatch for most items.
🏭 Why This Project Succeeded: The Thermokrupp Manufacturing Advantage
In-House Fabrication
We cut, roll, weld, and test in our Dadri factory. No subcontracting.
In-House Design
5 mechanical engineers. Custom drawings in 48 hours.
In-House Service
Factory-trained engineers across India. Not third-party.
📌 Ready to Discuss Your Specific Application?
Every drying, curing, or baking process is unique. This case study is just one example of how Thermokrupp engineers custom Hot Air Generators for exacting requirements.
Request a Free Process Consultation
Describe your application – we will provide a preliminary system design within 48 hours.
Case study reference: HAG-0324-PUN | IBR approved | 5-year warranty eligible
© 2024 Thermokrupp Engineers. All specifications and project details shared with client permission. Individual results may vary based on application.