10 industrial applications of temperature controller

Thermal controllers are becoming increasingly popular in industry, offering precise, reliable temperature control for a wide variety of industrial applications.

From testing laboratories in the pharmaceutical industry to the manufacture of polymers and plastics, there are many sectors where temperature controllers can help optimize performance and productivity.

In this article, we will look at 10 industrial applications of the temperature controller in which it can significantly improve industrial processes.

The use of temperature controllers in the pharmaceutical industry

In the pharmaceutical industry, traceability of measurements at all stages of the manufacturing process is essential to ensure that all products and experiments comply with strict quality and efficiency regulations.

Pharmaceutical companies can ensure that the manufacture of each product or medicine is carried out in accordance with the relevant standards, by equipping themselves with temperature controllers. In addition to allowing traceability of accurate measurements, these instruments contribute to the proper functioning of equipment and various types of laboratory research works.

Temperature controllers are indispensable instruments for the success of many chemical manufacturing processes.

• In chemical reactors to ensure an optimal and safe reaction.
• In distillation processes for efficient separation of the different components.
• In product drying processes to extend product life.
• In polymerisation processes for a homogeneous and controlled reaction.
• In oxygen reduction processes to avoid product decomposition. This technique makes it possible to preserve vegetable oils, organic solvents and polymers.

Temperature measurement control in laboratories is also used in storage systems to maintain the stability and quality of the chemical elements produced.

Temperature control is an important factor to consider for the chemical industry, as the installation of a temperature controller can greatly  improve the manufacturing process and the results of experiments conducted.

Temperature controllers for petroleum applications

• Refining:this process involves converting pure oil into finished products such as petrol, diesel and heating oil by passing it through a distillation tower and heating to very high temperatures.
• Catalytic cracking: this technique is used to convert heavier hydrocarbons into lighter petrochemicals by subjecting them to a temperature of around 500°C.
• Steam injection for oil recovery: this technique is used to extract heavy, viscous oil from underground reservoirs by injecting high-temperature steam to thin the oil.

Temperature controllers for gas applications

• Liquified natural gas: this process involves cooling natural gas to very low temperatures to turn it into a liquid that can be easily stored and transported.
• Hydrogen production: this technique often involves reacting methane with steam to produce hydrogen and carbon monoxide.
• Natural gas processing: when industrial gases such as oxygen or nitrogen are produced, they must be purified to the required specifications under precise pressure and temperature conditions for successful purification.

The installation of temperature controllers ensures that conditions are optimal for the extraction and processing of oil and gas. Fast and reliable temperature control increases efficiency in the various stages of fossil fuel processing.

Once produced, the pulp has to be converted into sheets for subsequent draining and drying, and this manufacturing process can be improved by temperature controllers.

• Forming: the paper pulp is very wet and is drained on a wire mesh before being pressed to reduce its humidity.
• Drying: the paper sheet is passed through dryers where the temperature reaches 120°C.
• Calendering: the paper is passed between heated rollers to smooth and protect it. Depending on the temperature of the rollers, the paper will look different.
• Rolling: the paper is rolled up to form reels which are cut to the customer's requirements.

The papermaking process is a complex operation requiring a precise control loop of the temperature variable to ensure continuous production. Otherwise, papermakers risk costly downtime and poor end-product quality. To maintain a constant temperature throughout the papermaking process, companies need reliable and efficient temperature management systems.

Firstly, the machines that produce the packaging use a heating device to shape and form the different types of packaging:

• Thermoforming machines for the formation of plastic products such as cans and bags.
• Blow moulding machines for the production of plastic bottles with controlled temperature.
• Injection moulding machines for the production of specifically shaped plastic parts.

The importance of control in optimizing temperature settings for different packaging processes cannot be underestimated.

To fill manufactured containers, the packaging industry uses equipment where the temperature must be controlled so as not to alter the quality of the packaged product:

• Liquid filling machines: for filling liquid products such as beverages, sauces and oils.
• Autoclaves for the sterilisation of food and medical products, for example.

Finally, packaging plants also use machines to seal packages in order to extend the shelf life or to protect the sealed materials:

Heat-sealing machines for sealing packages under vacuum or protective atmosphere.

• Welding machines for sealing plastic and paper packaging.
• Bag sealing machines for sealing plastic and paper bags for food, chemicals and other products.
• Heat-sealing machines for sealing paper and plastic packaging using a heating element.
• Induction sealing machines for sealing paper and plastic bags using an electromagnetic field to heat the plastic part of the container lid.

Temperature regulation and control of packaging machinery and packaging is essential to ensure the highest level of quality in the finished product.
Manufacturers in this sector should therefore consider the installation of reliable and accurate temperature controllers to ensure the best performance for their product packaging and sealing.

The principle of operation of an industrial boiler is simple. 

A heating system boils the water in the boiler tank. This boiling water then produces steam. This steam turns a turbine, which is connected to an alternator to generate electricity. It's important to maintain a balance in the water level in an industrial boiler's drum when generating electricity. The combination of steam flow and feed water flow with the drum level element enables more precise regulation of the amount of water inside the drum, improving monitoring.

The techniques used to create glass vary according to the different types - hollow, flat or technical - but the production process remains fundamentally the same.

• Preparing the "batch": this stage involves crushing and mixing the various raw materials - known as "batch" - that will make up the glass.
• Melting: the glass is fired at a temperature that gradually rises to 1,300° - 1,400°C.
• Refining and homogenisation: the glass is subjected to a higher temperature in order to liquefy it and correct any defects and bubbles in the composition.
• Embering: the temperature of the glass is lowered to make it more malleable and give it a specific shape.
• Moulding: either by the Press-Blow technique or the Blow-Blow technique.
• Firing: the glass will first be heated to 650°C and then heat treated at approximately 500° to 550°C.
• Quality control: the glass is checked according to various criteria to certify its quality.

Temperature control is an essential part of the glassmaking process and requires precise management. Without an efficient and reliable control system, product manufacture can be compromised, since temperature ranges are very high and very precise at every stage of the industrial process. Thanks to precise temperature controllers, manufacturers in the glass industry can ensure, among other things, efficient heat treatment in a controlled atmosphere, as well as reliable and precise control of their process temperature.

Let's take the case of the bakery sector

As well as continually delivering top-quality products to consumers at the right price, they also have to pay attention to their costs and find ways to optimize their performance.

With a pid temperature management system, it becomes possible for industrial oven manufacturers to guarantee the production quality and yield of bakery ovens.

With regard to packaging, palletising, stock management and transport of food products to distributors, wholesalers-distributors must not break the cold chain principle.

In order to guarantee the quality of the stored items and to avoid spoilage, the storage areas must be kept within specific temperature ranges. In addition, all vehicles used for transport and refrigerated chambers should be equipped with temperature-measuring devices to maintain the cold chain.

All the more so as the components are subjected to extreme and precise temperatures as part of their manufacturing process.

• Thermal regulators can be used in several stages of electronic component manufacturing, in particular during :
• SMD soldering to maintain a stable temperature when soldering components onto a wafer.
• Reliability testing to simulate extreme environmental conditions for electronic components.
• The manufacture of memory devices to maintain a stable temperature during heat treatment of materials.
• Heat treatment for electronic component rings, to improve reliability and performance.
• Drying of components in drying chambers to dry coatings and material layers on printed circuit boards.
• Housing soldering to maintain a stable temperature for soldering plastic or metal housings to electronic components.
• Accelerated aging test to simulate the impact of aging on the performance of electronic components at high temperatures.

Precise temperature control during all these phases of production results in better quality and longer life of the final product.

The polymers used in the design of plastics are mainly derived from products of the oil and gas industry.

• Fractional distillation: oil is subjected to very high temperatures to extract naphtha, a liquid used in the production of plastics.
• Cracking: this step breaks down the large hydrocarbon molecules in the naphtha into smaller components by heating them to very high temperatures and then cooling them. The resulting small molecules form polymers which are needed to make the plastic.
• Moulding: the polymers are injected into a mould to form the final shape. The product is then cooled before being removed from the mould.
• Cooling: The finished product must undergo a cooling or freezing process to ensure optimum quality and use.

From refining oil to cracking hydrocarbons into smaller molecules for the manufacture of plastics, temperature measurement and control must be accurate and reliable at every stage of the process.

Why invest in Fuji Electric temperature control and management equipment?