At Thermal Fluid Systems,
we are an established supplier of heat energy equipment for a range of industries. We have an extensive background working with food processing applications and applied our knowledge to engineer and build a completely customized hot oil system that provided precisely accurate temperature control for a maker of protein bars.
The equipment highlighted here consists of a high-efficiency, gas-fired 640,000 BTU hot oil heating system with loop process temperature controls. Operating in the 200°F to 350°F temperature range at 75 psi, it features a 150-gallon capacity and utilizes food-grade thermal fluid. Integrated into a processing line that converts peanuts into a mixture for a protein bar, it maintains process temperatures at precise set points to ensure that the final product has a consistent taste, texture, and nutritional profile. To support fluid cleanliness and extend system life, the design includes advanced fluid filtration and heat filtration components.
One of our challenges was to design a system that fits neatly into the available space at the food processing plant. We compactly arranged the components while still leaving adequate accessibility for operation and maintenance. Another issue arose while the build was already in progress. The client had initiated several process changes that compelled us to re-design the control system, but the agility and flexibility of our process engineers allowed us to easily overcome this issue at no extra cost to the customer. A dedicated fluid filtration system was also incorporated to maintain thermal stability and minimize downtime.
Built to ASME and NFPA standards, we completed the design and fabrication of this skid-mounted heater with integrated process controls in only 12 weeks. This turnkey system provides reliable operation, ensuring the processor produces a consistently high-quality product according to their recipe.
Importance of Fluid Filtration in Food-Grade Thermal Systems
Fluid filtration plays a critical role in maintaining system performance and food safety. Thermal oil used in food processing must stay clean to deliver consistent heat transfer and avoid contamination. Without filtration, particulates can build up, leading to reduced efficiency, pump wear, and risk of product exposure. Integrating fluid filtration systems helps remove carbon, dirt, and other impurities that naturally develop over time, keeping thermal fluid within recommended operating standards.
Heat Filtration and System Cleanliness
Heat filtration refers to removing contaminants from the thermal fluid that can impair heat transfer. In this project, high-temperature strainers and inline filters were used to protect the heater and downstream equipment. By minimizing sludge and oxidation buildup, these systems help maintain consistent fluid temperatures and prevent fouling of process heat exchangers. This improves uptime and reduces fluid replacement costs.
Advantages of Custom Thermal Fluid Systems in Food Processing
- Indirect heating eliminates direct flame contact with food products, reducing the risk of scorching or contamination.
- Stable and accurate temperature control supports consistent product quality across batches.
- Integrated fluid filtration systems remove impurities, extending fluid life and helping prevent unscheduled maintenance.
- Clean thermal transfer reduces residue buildup inside heat exchangers and piping.
- Compact, skid-mounted designs save floor space and simplify installation in tight production areas.
- Systems can be configured for food-grade thermal fluids to support sanitary standards.
- Heat filtration helps maintain uniform heat distribution and protects equipment from fouling.
Applications Across the Food Industry
While this system was built for a peanut and protein bar production line, similar solutions apply to baked goods, snack foods, edible oils, and confectionery lines. Any process requiring clean, stable heat can benefit from this approach.
Let Your Heat System Work Clean, Not Hard with Thermal Fluid Systems
Ready to improve thermal performance in your food processing operation? Thermal Fluid Systems builds custom heating solutions with built-in fluid filtration and heat control to match your production needs. Contact us to discuss your application and see how a clean, efficient system can support long-term reliability. Our team is here to help with fast turnaround and proven results.