Immersion Heaters for Food Processing


Sesucof Manufacturing INC, Business Case Study: Immersion Heaters

Immersion heaters are the best way a food processing business can maintain a high-quality product and comply with governmental safety requirements. Immersion heating is a reliable and efficient solution for maintaining a dry, temperature controlled environment for food processing. Companies dealing with moisture control or psychometrics are finding immersion heating a welcome answer to the problem.

This case study searches out the problem a manufacturing site might have, controlling moisture in a facility. Wherever food is prepared, refrigeration and water are a necessity. Food processing environments should be sterile, and these conditions are difficult to maintain when moisture is not controlled. The development of pathogens is a danger. This problem increases in an environment where mass amounts of foods are produced. Immersion heating has proven in this study to be the best possible solution for these industries.

Challenge — Key Problems

To operate profitably in a food manufacturing business startup, a few key problems require solutions: 

1. Keeping equipment free of condensation
2. Preventing bacteria (Destroying spores in the active and dormant states)
3. Avoiding contamination
4. Removing moisture from the air
5. Maintaining constant temperatures
6. Reducing environmental issues

Why Immersion Heaters Are Important to Food Processing

Washing floors and walls is a necessity in food processing areas to eliminate pathogens and bacteria in the processing area; moisture must not be allowed to linger. There are several options for heating and drying in the food processing business. Many offer direct liquid heating immersion heater attachments that can be adjusted to fit reservoirs by way of welded or heat brazed fittings. Screw-Plug immersion heaters allow the user to insert the heaters into tanks for direct heating or into an opening to heat the air, which indirectly heats the tank.

The Screw-Plug Immersion Heater Solution

Sesucof Manufacturing INC will process food products using hot water at an ambient temperature of 180° F or Fahrenheit. Since heat distribution is influenced by, watt density, contaminants, heat density, viscosity, and screw plug immersion heaters. This food manufacturing plant requires tanks that hold 200 gallons of water to process the food. Heating the water in these tank to a temperature of 180° F (82.22 degrees Celsius(C)), starting from room temperature can prove challenging and time-consuming for other heating systems. Likewise, some other systems are harder to maintain than electric immersion heaters. The screw-plug immersion heater heat water quickly and efficiently utilizing control panels to alert operators to internal temperatures and water levels. A screw-plug immersion heating system with thermostat controls can heat foods and liquids without direct contact with the foods being processed.

A thermocouple sensor (RTD) measures fluid temperatures. This sensor manages up to 1000° F (540° C). This sensor is adequate to protect manufacturing tanks from overheating. It protects and helps extend use with a fluid level sensor to prevent damage from overheating.
During the process, heating elements maintain required temperatures with these controls. This device has a security mechanism that signals the computer if the system it is attached to can begin to overheat because of low water levels. The sensors, connected to a control panel allows for more fluid intake automatically and can trigger an automatic shutdown when fluid levels are not restored when systems to refill are inadvertently shut down before hazardous conditions can start.

The screw-plug immersion heater is practical in most sectors of the food processing industry, vegetable oil, mild liquids, grease, juice, some chemicals, as well as asphalts, gas, and petroleum products, which may need heating in some industries. These immersion heater elements are equipped or coated with corrosion resistant materials.

Sanitary Use of Screw-Plug Immersion Heaters & Sensors

Air does not reduce moisture without heat. Screw-plug immersion heaters could be the solution for practically every level of liquid heating in the food processing industry. Immersion heating is cost efficient when coupled with sensors and control panels, whether used with direct or indirect heating methods. This heating system is the fastest and most reliable way to heat liquids, solids, or gases used in the food processing industry.

Is the Screw-plug Immersion Heater Solution Realistic?

Screw-plug immersion heaters are a practical and realistic method of heating foods directly or indirectly through immersion heating. Heating foods to the desired temperature utilizing screw-plug immersion heaters and sensors are a reliable heating system even during shifts changes and overnight shutdowns, when necessary. Additionally, immersion heaters with attached sensors are often the most trusted solution for heating accuracy with or without human intervention.

Immersion Heaters Impact on the Organization

The correct use of immersion heaters and sensors can allow the company to comply with food safety standards and to produce a better product. When accurate temperatures are maintained, food products are safer and taste better. The consumer can be assured of product safety. Poor quality not only destroys the product but the reputation of the business.


The use of screw-plug immersion heaters with automated sensors is beneficial to better more reliable food processing.

Although, electric immersion heaters are more expensive to use than gas or oil heaters, electric immersion heaters coupled with sensors and control panels provide better accuracy and monitoring, thus eliminating the risk of uneven heating and possible contamination of food products sold to consumers. This effectively eradicates food poisoning lawsuits and ensures repeat customers because of high-quality products.
Immersion heaters additionally assist in the packaging process providing sterile containers. Jars, cans, and other packing devices can be kept sterilized in airtight temperature controlled staging areas. 
Immersion heaters are the most effective and economical method to ensure the accuracy of heating and packaging.
Consider industrial heating elements from WATTCOTM for all your industrial heating needs. Call 1-800-4-WATTCO or get a no-obligation 24-hour quote using a Request for Information today.

Latest blogs

Common Industries that Wattco works with

Case Studies View All

5 Fundamental Rules for Designing Efficient Heat Transfers
Considering these basic rules for designing thermal heat transfers will expand a project’s product...
Read More..

A Review of Industrial Heaters: Oil and Gas industry Case Study
About Industrial Heating The industrial revolution has significantly contributed to the development ...
Read More..

Advantages and Limitations of Digital Control Panels for Industries
Digital control panels are widely used in industries to monitor and control system variables. Humidi...
Read More..

Air Duct Heaters
Air duct heaters are commonly used in the HVAC industry. They provide supplementary heat to the deli...
Read More..

Alternatives to Direct Immersion Heaters
  Although immersion heaters are most often the best possible solution for tank content heating, so...
Read More..

Wattco News View All

4 Advantages of Skid Systems in Industrial Heating Processes
Many industrial heating processes involve maintaining a consistent temperature in a vessel to protec...
Read More..

4 Common Causes & Solutions of Circulation Heater Fouling
If you have noticed a decrease in the efficiency of your circulation heater, the most common culprit...
Read More..

A Closer look at Circulation Heaters
Wattco manufactures and designs circulation heaters for maximum efficiency. As a result, these heate...
Read More..

A Closer Look at Immersion Heaters for Tanks
Heating storage tanks is an important application of electric immersion heaters. Tank heating is a p...
Read More..

A Closer Look At Load Banks
Load banks are essential for applications in a variety of industrial applications, especially for te...
Read More..

Most Popular Blogs View All