When project schedules are tight, waiting on approvals can slow everything down—and add unnecessary cost. That’s where Enerquip’s national Canadian Registration Number (CRN) for 8” NPS heat exchanger designs makes a real difference for customers across Canada.
Enerquip now holds a CRN for all Canadian provinces, except Alberta, for our stock and standard-design 8” NPS units. The result is no waiting for the CRN to be issued, faster order processing, and more predictable delivery timelines. Enerquip has also absorbed the upfront cost of obtaining this CRN and is passing those savings directly on to customers.
What “National CRN” Means
In this case, national means Enerquip’s design is registered across most Canadian provinces under a single CRN, rather than requiring a new CRN application for each project or jurisdiction. This simplifies compliance and removes a common bottleneck in the procurement process.
Note: Alberta is excluded at this time. If your project is located in Alberta, contact Enerquip to discuss available options.
What’s Covered Under Enerquip’s National CRN
This CRN applies to a wide range of Enerquip 8” NPS heat exchanger configurations, including:
Five stock 8” NPS steam-to-liquid units: available for same-day or next-day shipment
Standard design 8” NPS steam-to-liquid units: shipped at current standard lead times (typically 8-9 weeks) or expedited when available
Standard design 8” NPS liquid-to-liquid units: ¾” tubes, available at standard or expedited lead times
3-A compliant 8” NPS steam-to-liquid units: ¾” tubes, available at standard or expedited lead times
Why This Saves Time and Money
A typical CRN can take weeks—or even months—to obtain and may cost upwards of $1,500. With Enerquip’s national CRN already in place for stock and standard-designed 8” NPS units, customers can bypass that process entirely. Instead, the cost to reuse a CRN is typically around $250, delivering real savings while keeping projects on schedule. That means:
Shorter project timelines
Fewer administrative delays
Reduced compliance-related costs
Less risk of schedule-driven overruns
It also gives engineers and procurement teams more flexibility, with hundreds of possible 8” NPS configurations registered under a single CRN.
Built for Speed Without Compromising Compliance
Enerquip’s national 8” NPS CRN supports stock units, standard designs, and aids in expedited delivery options, giving customers a faster path to compliant equipment while maintaining the quality and performance Enerquip is known for.
Food manufacturers carry a critical responsibility: delivering products that are clean, safe, and free from contamination. With consumer trust on the line—and increasingly stringent food safety regulations—preventing food recalls must be a top operational priority.
This guide covers the key steps every food processing facility should take to reduce contamination risks, maintain sanitary operations, and safeguard brand reputation.
Why Preventing Food Recalls Matters
Even with high safety standards, mistakes and contamination events can occur. Undeclared allergens, improper sanitation, and microbial contamination continue to trigger food recalls across the industry. Some of the most common foodborne pathogens include:
E. coli
Listeria monocytogenes
Salmonella
These contaminants can cause severe illness and even death if introduced into food or dairy products. According to the U.S. FDA, millions of Americans suffer from foodborne illness each year—reinforcing the importance of preventive controls.
Beyond the threat to public health, food recalls can be financially devastating. A single recall can cost a company millions of dollars in direct expenses—not including long-term damage to brand reputation and consumer trust.
1. Conduct Regular Process Reviews
A sanitary production process is the foundation of safe food manufacturing. To reduce recall risks, facilities must perform regular reviews of their equipment, workflows, and preventive controls.
Key process-review best practices include:
Performing routine vulnerability assessments: Identify contamination risks—such as product flow bottlenecks, dead legs in piping, or equipment that is difficult to clean thoroughly.
Scheduling ongoing inspections: Even during peak production periods, visual checks help monitor equipment condition and catch early warning signs. Follow quick inspections with more detailed evaluations to ensure thorough oversight.
Reassessing compliance with food safety regulations: The Food Safety Modernization Act (FSMA) requires food processors to implement preventive controls and maintain documentation. Regular reviews ensure your operations stay aligned with regulatory standards.
2. Invest in Sanitary, Easy-to-Clean Equipment
Equipment design plays a major role in preventing contamination and supporting efficient, hygienic workflow. Two factors matter most:
Sanitary design and construction
Proper cleaning and maintenance
Sanitary design essentials
High-quality sanitary equipment includes:
Smooth, crevice-free surfaces
Rounded edges to prevent product buildup
Corrosion-resistant materials that minimize fouling
Stainless steel shell and tube heat exchangers are widely used in food and dairy operations because they meet these criteria and deliver excellent thermal performance.
Heat exchanger design options
Straight-tube heat exchangers: Fewer corners mean easier cleaning and reduced risk of fouling.
U-tube heat exchangers: Slightly more complex to clean, but highly effective with the right process and CIP system.
Cleaning-in-Place (CIP) integration
CIP systems clean equipment without disassembly by circulating hot water, steam, and cleaning chemicals through sanitary heat exchangers. CIP offers:
Your food safety systems are only as strong as the equipment you rely on. Working with a trusted sanitary equipment manufacturer ensures your processes meet strict hygienic standards.
Why material choice matters
Cross-contamination risks increase when equipment comes into contact with non-food-grade materials like carbon steel. Leading sanitary manufacturers avoid these materials to ensure product integrity. Enerquip, for example, manufactures product-contact surfaces exclusively from stainless steel and offers fabrication that meets 3-A Sanitary Standards and other food industry requirements.
Optional lower Ra or electropolished finishes for ultra-clean applications
Protect Your Brand by Partnering with Experts in Sanitary Heat Exchangers
The right equipment and preventive processes significantly reduce the risk of contamination and costly recalls. If you’re evaluating your current setup or designing a new process, collaborating with experienced heat exchanger specialists can help optimize safety and efficiency.
Enerquip’s team can guide you through custom design options that support sanitary production, product integrity, and long-term reliability.
Connect with Enerquip’s experts to explore how custom shell and tube heat exchangers can enhance food safety and reduce recall risk in your facility.
Condensing economizers can help recover latent heat.
Boilers are essential in many industrial operations—but they can also be major sources of wasted heat and unnecessary energy expense. One of the most effective ways to reclaim lost energy is by installing a condensing economizer—heat-recovery equipment that captures water vapor from boiler exhaust and converts it into usable thermal energy.
Condensing economizers are used across a wide range of industries, including:
Food and beverage processing
Pulp and paper mills
Hospitals and healthcare facilities
Greenhouses
District heating systems
Industrial manufacturing
For operations that rely on steam or process heat, adding a condensing economizer can significantly reduce fuel consumption, cut utility costs, and support sustainability goals.
What Is a Condensing Economizer?
A condensing economizer is a heat-recovery unit that cools boiler flue gas below its natural dew point to capture both sensible heat (from the hot gas itself) and latent heat (released when water vapor condenses).
In a typical natural-gas boiler, flue gas exits the stack at temperatures around 250°F or higher. Cooling it below 135°F, the dew point of water vapor, allows the economizer to reclaim a substantial amount of energy that would otherwise be lost.
This recovered heat can then be used for:
Preheating boiler feedwater
Domestic or process hot water
Space heating
Other low-temperature process needs
How Condensing Economizers Work
When flue gas passes through the economizer, it is cooled using either a heat-exchange surface or direct water contact. As the vapor condenses, the latent heat released is transferred into a water stream—providing clean, efficient, and reusable energy.
The amount of recoverable heat depends on factors such as:
Fuel type
Flue gas temperature
Boiler load
Economizer design
Water temperature entering the system
Recovering latent heat can increase boiler efficiency dramatically, often by 10% or more, depending on operating conditions.
Types of Condensing Economizers
Two primary designs are used in industrial applications, each with distinct advantages.
1. Direct Contact Condensing Economizers
In this design, hot flue gas enters a spray chamber where it comes into direct contact with cool water droplets.
Benefits:
Very high heat-transfer efficiency
Effective water recovery
Simple mechanical design
Limitations:
Heats water only to ~140°F
Requires a mist eliminator to prevent droplet carryover
Direct-contact units are ideal when there is a consistent need for low-temperature process water.
2. Indirect Contact Condensing Economizers
Indirect systems use a shell and tube heat exchanger or similar technology to cool the flue gas without mixing it directly with water.
Benefits:
Can heat water up to ~200°F
Can cool flue gas to as low as ~75°F
Suitable for a wider range of processes
Because they deliver higher water temperatures, indirect economizers are especially useful for preheating boiler feedwater or supporting space and process heating loops.
Example: A food processing facility installed an indirect condensing economizer to reduce its deaerator steam load. By lowering flue gas temperature from 300°F to 120°F, the unit recovered 2 million BTU/hr and cut deaerator steam demand from 5,000 to 1,500 lbs/hr—resulting in substantial energy and cost savings.
Key Considerations When Selecting a Condensing Economizer
1. Water Quality and Neutralization
Condensate from flue gas is often acidic and must be neutralized before discharge or reuse. Common treatment options include:
External heat exchangers
pH control systems
Filtration or membrane treatment
2. Materials of Construction
Because condensate can be corrosive, selecting durable materials is critical. Stainless steel and corrosion-resistant alloys are commonly used to ensure long-term performance in natural-gas boiler systems.
3. Available Space and Operating Conditions
Not all operations will benefit equally from economizer installation. For example:
Facilities that already reclaim most blowdown heat may see limited additional savings.
Plants with minimal demand for low-temperature water may benefit more from an indirect design than a direct-contact system.
A site assessment helps determine the best approach for maximizing heat-recovery potential.
Partnering With Experts for a Customized Solution
Condensing economizers are rarely one-size-fits-all. Each facility has unique operating temperatures, fuel types, water demands, and mechanical constraints.
Working with experienced heat-transfer engineers—like the team at Enerquip—ensures that your condensing economizer or shell and tube heat exchanger is designed, fabricated, and optimized specifically for your process.
If you’re exploring ways to reduce energy consumption, improve boiler efficiency, or meet sustainability goals, a custom heat-recovery solution may deliver substantial long-term value.
Thermal expansion is an unavoidable factor in the operation of shell and tube heat exchangers. As temperatures rise, the tubes and shell naturally expand — but not always at the same rate. Without proper compensation, these dimensional changes can lead to stress, distortion, leaks, or even catastrophic equipment failure.
Expansion joints are a proven solution to reduce this thermal stress. However, not all expansion joints are created equal. Understanding the differences between metal expansion bellows and packed slip expansion joints will help you determine which design best fits your application.
Why Expansion Joints Matter in Heat Exchangers
Because tubes and shells often expand differently due to material properties and temperature variations, unmitigated thermal movement can create:
Tube-to-shell interference
Damage to the tube sheet
Excessive pressure on welds and structural components
Long-term reliability and maintenance issues
Expansion joints absorb this movement, protecting the mechanical integrity of the exchanger and extending overall service life.
Two of the most commonly used designs are metal expansion bellows and packed slip expansion joints. Each option offers unique advantages — and important limitations.
Metal Expansion Bellows
Metal expansion bellows, sometimes called packless expansion joints, absorb movement through their flexible, convoluted design. They can be internally or externally pressurized, and their wall thickness varies based on the requirements of the operation.
Internally Pressurized Bellows
Internally pressurized bellows are popular because they:
Are simple to inspect
Offer a cost-effective solution
Work well for modest thermal expansion requirements
However, these bellows are not ideal for large axial movements. Under high pressure or long-length conditions, they can experience instability, often referred to as “squirm,” which may lead to premature failure.
Best for: Applications with small to moderate axial movement, limited pressure, and a need for easy inspection.
Externally Pressurized Bellows
Externally pressurized designs provide:
Significantly higher axial movement capability
Protection within a robust outer pipe
Increased safety because the outer pipe contains pressure and shields the system if the bellows fail
Options for self-draining configurations and leakage-limiting features
These units excel in environments with high thermal stress where internally pressurized designs may not perform reliably.
Best for: High-movement, higher-pressure applications where reliability and safety are top priorities.
Choosing the Right Bellows Wall Thickness
Bellows are engineered with thin, medium, or thick walls depending on the operational loads, pressure, and flexibility required.
Thick-Walled Bellows (4–13 mm)
Extremely durable
Limited flexibility
Typically include only two to three tall convolutions
Often used in fixed tube sheet heat exchangers
Best for: High-pressure applications where movement is relatively small.
Medium-Walled Bellows (2–4.5 mm)
Designed as a balance between strength and flexibility, medium-walled bellows:
Offer more durability than thin-walled models
Provide more flexibility than thick-walled options
Use convolutions of moderate height
Best for: Situations requiring a compromise between pressure capacity and movement.
Thin-Walled Bellows (0.5–2 mm)
Highly flexible
Allow many convolutions with shorter heights
More vulnerable to damage if not properly reinforced
Manufactured using hydraulic forming or cold rolling
To increase strength, these can be built with multi-ply layers or supported by restraining rings.
Best for: Applications requiring significant movement with lower pressure demands.
Packed Slip Expansion Joints
Packed slip expansion joints (or simply slip joints) use a sliding sleeve that moves axially within the exchanger shell. Packing material between the sleeve and shell minimizes leakage while allowing movement.
Benefits of Packed Slip Expansion Joints
Excellent for pure axial movement
Commonly paired with packed floating head designs
Often more economical than metal bellows
Packed slip joints are mechanically simple and effective for applications with straightforward movement requirements.
Limitations and Considerations
Only accommodate linear axial movement — no lateral, angular, or rotational movement
Packing materials can wear over time, increasing leakage risk
Not recommended for processes where zero leakage or cross-contamination is critical
Best for: Budget-conscious applications where small leaks are tolerable and movement is strictly axial.
Which Expansion Joint Is Right for Your Heat Exchanger?
The ideal expansion joint depends on a combination of factors, including:
Expected thermal movement
Pressure conditions
Required leak-tightness
Inspection and maintenance needs
Orientation and design of the heat exchanger
For many operations, externally pressurized bellows offer the best flexibility and durability. In others, packed slip joints provide a simpler and more cost-effective option.
Need Expert Guidance?
Selecting the right expansion joint can be complex. A knowledgeable engineer can evaluate your thermal loads, material compatibility, and operational requirements to ensure your heat exchanger performs reliably for the long term.
The engineering team at Enerquip specializes in custom heat exchangers and thermal-stress solutions. If you’d like help determining the most effective expansion joint for your application, we invite you to contact us today.
How to Prepare Your Asphalt Plant for Success During the Off-Season
When spring hits, contractors are ready to pave and roof—and your asphalt plant needs to be just as ready. Winter might be your slower season, but it’s also the best time to prep your heating equipment so you’re not scrambling when the busy months roll in.
Want to avoid costly downtime when demand is high? Here are six smart ways to get ahead and ensure your asphalt heating system is ready to deliver.
1. Stay On Top of Maintenance
Just because your system isn’t running at full capacity doesn’t mean it should be out of sight, out of mind. The off-season is ideal for stepping up your maintenance game.
Fewer day-to-day demands mean more time for inspections, tune-ups, and addressing wear before it becomes a bigger issue. Use this time to establish a solid maintenance routine that keeps your system running smoothly year-round.
Know something’s on the verge of failing? Don’t wait. Schedule repairs now, when downtime is less disruptive—and likely less expensive.
As your production season winds down, assess your heating system and take note of any worn components or issues that popped up during peak use. Prioritize those repairs before you’re back in high gear.
Efficiency upgrades often get pushed aside when production is full steam ahead. Use the off-season to tackle changes that can boost output, cut costs, or streamline operations.
From better insulation to heat recovery systems, even small tweaks can add up.
Sometimes repairs just aren’t enough—and constant patchwork becomes more expensive than a full replacement. If you suspect your heating system is nearing the end of its life, the off-season is the time to act.
Swapping out equipment in the winter minimizes interruptions and sets you up for a stronger start in spring.
Need a new heater or system component? Researching, requesting quotes, and selecting the right solution takes time—something you’re short on during peak season.
Use this quieter window to explore your options and make informed decisions that won’t delay your operation later on.
Nothing slows production like waiting on a part. Stocking commonly needed spares—like gaskets, O-rings, and thermocouples—can save you from days of unplanned downtime.
If your plant doesn’t have a spare parts program, now’s the perfect time to create one. If you do, take time to review and restock.
Prevention and preparation are your best defense against downtime when business picks up. Use the off-season to fix known issues, make smart upgrades, and get your equipment running like new.
And when spring gets close? Fire things up early. Test your systems and address any final hiccups before customers are counting on you.
Need New Heating Equipment? Whether you’re replacing outdated systems or expanding capacity, our team can help you find the right heating solution for your asphalt plant. Request a quote today.
The holidays are packed with timeless traditions—family gatherings, festive decorations, and the foods we wait all year to enjoy. Think creamy eggnog, rich pumpkin pie, and tangy cranberry sauce. But long before these dishes hit your plate, they go through carefully controlled food processing steps to ensure they’re safe, shelf-stable, and delicious.
Let’s take a behind-the-scenes look at how thermal processing plays a key role in preparing these seasonal staples.
Eggnog: Pasteurization is Key
Eggnog combines two ingredients known for being finicky in food safety: milk and eggs. Because both can carry harmful bacteria, pasteurization is a must.
There are two common methods for pasteurizing eggnog:
Batch pasteurization: Heating the mixture to 155°F for 30 minutes.
High-temperature, short-time (HTST) pasteurization: Heating to 175°F for 25 seconds.
Both methods help eliminate pathogens like Salmonella and E. coli, making that festive glass of eggnog safe to sip.
Canned Pumpkin: More Than Just Pumpkin
Spoiler alert: your pumpkin pie may not be 100% pumpkin. Canned “pumpkin” often includes a blend of pumpkin and sweet squash—perfectly legal and very tasty.
What matters most is food safety. Pumpkin puree falls into a category known as low-acid canned foods (LACFs), which means its pH (typically 4.9–5.5) is high enough to allow for bacterial growth if not handled properly. That’s why these products must go through high-heat processing—often pressure-cooked inside the can—to eliminate spores like Clostridium botulinum, which can cause botulism.
The production process also includes:
Washing and sanitizing
Removing stems, seeds, and pulp
Chopping, steaming, and mashing
Sterilizing and canning
It’s a complex journey, but all those steps are essential for that smooth, pie-ready texture.
Cranberry Sauce: Naturally Acidic, Still Needs Processing
Cranberries are naturally high in acid (around 2.4 pH), which makes them a less likely host for some dangerous bacteria. Still, pathogens like Salmonella can thrive if products aren’t processed correctly.
That’s why cranberry juice and sauce are typically pasteurized. It not only extends shelf life, but ensures these tangy treats are safe to eat. In some cases, unpasteurized juice must carry a warning label to alert consumers of potential risks.
Why Equipment Matters
No matter the product—milk, juice, or squash—quality food processing equipment is critical. Consistent temperature control, cleanability, and durability are all essential for safe, efficient pasteurization.
Stainless steel is a top choice for food-grade equipment thanks to its:
Corrosion resistance
Smooth, easy-to-clean surface
Compatibility with CIP (clean-in-place) systems
It’s the material of choice for many processors looking to meet strict hygiene and safety standards while maintaining efficiency and reliability.
Looking Ahead
Holiday dishes may be rooted in tradition, but the equipment behind them is anything but old-fashioned. As food safety regulations evolve and consumer expectations grow, so does the demand for high-performance, hygienic processing systems.
At Enerquip, we design and fabricate stainless steel shell and tube heat exchangers trusted by food and beverage manufacturers across the country. Whether you’re processing dairy, juice, or purees, we’ll help you find a thermal solution that meets your standards—and keeps your customers safe.
Heat transfer fluid (HTF) carries thermal energy through your exchanger system, either on the tube side or shell side, facilitating heating or cooling of your process materials.
Selecting the ideal heat transfer fluid is critical to the performance, safety, and longevity of your shell and tube heat exchanger. The right fluid can enhance efficiency, reduce maintenance needs, and extend equipment life. The wrong one can cause fouling, corrosion, or poor heat transfer.
Common HTF options include:
Water and steam
Glycol-based fluids
Silicone-based fluids
Mineral oils
When choosing the right fluid for your operation, it’s important to look beyond basic compatibility. Below are the main considerations to guide your decision.
1. Cost and Availability
While performance should always take priority, cost and accessibility play important roles in HTF selection. You need a fluid that fits your budget and can be easily replenished when maintenance or replacement is required.
Glycol-based fluids are popular across many industries for their cost-effectiveness and wide availability. They can be safely mixed with water to lower freezing points and raise boiling points, providing excellent temperature control.
Silicone-based fluids are more expensive but offer superior thermal stability and longevity, especially at high operating temperatures.
No other HTF can be safely diluted with water, which makes glycol a particularly flexible choice.
2. Proper Allocation: Shell side or Tube side?
The placement of your HTF—on the shell side or tube side—can have a major impact on efficiency, safety, and ease of maintenance. The right choice depends on factors like pressure, fouling potential, and corrosion risk.
When to Use the Tube side
Your HTF is better suited for the tube side if it is:
High pressure
Prone to fouling
Corrosive
Likely to solidify
Tubes are easier and less costly to clean, remove, or replace than shells. High-pressure fluids are also easier to control within smaller-diameter tubes, which allows for safer and more efficient operation.
When to Use the Shell side
If your fluid has a low pressure drop, high viscosity, or will condense during operation, it may perform better on the shell side. Proper baffle placement and shell design can accommodate these characteristics while maintaining optimal heat transfer.
3. Regular Monitoring and Maintenance
Even the best HTFs degrade over time due to thermal stress, oxidation, or contamination. Regular monitoring ensures continued performance and prevents costly damage.
As an HTF breaks down, it may:
Lose viscosity, requiring more energy to pump through the system.
Reach higher temperatures, increasing the risk of overheating.
Accelerate equipment wear and corrosion, reducing exchanger lifespan.
Implement a routine fluid testing schedule to check for viscosity changes, contamination, or signs of degradation. Replacing degraded HTF early helps protect both your equipment and your product quality.
Plan Your Heat Exchanger for Long-Term Success
Selecting the right heat transfer fluid is just one part of designing a safe and efficient shell and tube heat exchanger. The overall performance depends on factors such as:
Process application and working conditions
Material compatibility
Cleaning and maintenance requirements
Sanitary or industrial design needs
At Enerquip, our experienced engineers design and fabricate shell and tube heat exchangers tailored to your process. We serve industries ranging from food and beverage to pharmaceutical, oil and gas, and industrial processing.
Whether you need help selecting the best HTF or designing a custom exchanger, our team can ensure your system operates efficiently and safely. Contact us today.
When it comes to industrial process heating, both steam boilers and thermal fluid (hot oil) heating systems have long served as dependable solutions. However, as efficiency, safety, and cost-effectiveness become top priorities across industries, more facilities are discovering that thermal fluid systems offer significant advantages over traditional steam setups.
Let’s take a closer look at how hot oil systems compare to steam boilers—and why so many manufacturers, processors, and production facilities are making the switch.
1. Greater Energy Efficiency
Hot oil heating systems operate on a closed-loop design that minimizes heat loss and maximizes energy transfer. Unlike steam, which must constantly convert water to vapor and then back to liquid, thermal fluids circulate continuously—providing consistent heat with less fuel consumption.
This efficient operation allows plants to:
Achieve higher operating temperatures (up to 650°F) without pressurization.
Reduce fuel costs thanks to improved heat transfer and lower system losses.
Maintain steady, uniform temperatures that enhance process control and product quality.
In short, thermal fluid heaters deliver more usable heat energy to your process with less energy input.
2. Lower Maintenance and Operating Costs
Steam systems require frequent attention—managing water treatment, maintaining condensate return systems, and ensuring proper blowdown to remove impurities. Each of these steps takes time, resources, and additional equipment.
Hot oil systems simplify operations by eliminating many of these ongoing requirements:
No water treatment chemicals or deaerators needed.
No steam traps or condensate handling equipment to maintain.
No blowdown losses or water disposal concerns.
Because thermal fluids do not corrode piping or components, system longevity increases while maintenance downtime decreases—resulting in lower lifecycle costs and improved system reliability.
3. Enhanced Safety and System Reliability
Steam boilers must operate under high pressure to reach elevated temperatures, which increases the risk of leaks, explosions, and other safety concerns. Thermal fluid heaters, on the other hand, achieve similar or higher temperatures at low or even atmospheric pressure.
This low-pressure design:
Reduces risk to personnel and equipment.
Simplifies compliance with safety regulations.
Minimizes mechanical stress on system components.
Additionally, thermal fluids won’t freeze in cold climates and don’t cause corrosion, which helps protect critical infrastructure and prevent costly system failures.
4. Flexibility and Easy Integration
Hot oil systems can be installed as new systems or integrated into existing operations with relative ease. Their closed-loop design and smaller footprint make them ideal for a wide range of industrial applications—from chemical processing to asphalt production.
Because they operate efficiently and cleanly, thermal fluid heaters are also well-suited for facilities aiming to meet sustainability or emission-reduction goals.
5. Long-Term Cost Savings
While the initial setup costs for a thermal fluid system can be comparable to a steam boiler, the operating savings quickly add up. Lower fuel usage, reduced maintenance, and the absence of water treatment expenses all contribute to a lower total cost of ownership over time.
In addition, many facilities appreciate the simplicity of operation. In most states, thermal fluid heaters do not require a full-time, licensed boiler operator, reducing labor costs without compromising safety or performance. This can save upwards of $80,000 a year. Also with a thermal fluid heater, there is no need for a pretreating skid ($40,000), or deaerator ($40,000), or chemical injection system ($15,000), saving even more.
A Smarter, More Reliable Way to Heat
Thermal fluid heating systems offer a combination of efficiency, safety, and reliability that’s hard to match with traditional steam boilers. For many facilities, switching to hot oil heating means less maintenance, fewer operational interruptions, and greater control over critical processes.
Whether you’re looking to improve efficiency, reduce maintenance costs, or modernize your plant’s heating system, a thermal fluid heater may be the ideal solution. Contact us to get started today.
When it comes to modernizing or upgrading industrial heating systems, retrofitting is often one of the first options considered. Whether you’re repairing an aging system, improving performance, or repurposing equipment for a new process, retrofitting can be an effective way to extend the life of your investment.
However, while retrofitting offers many advantages, it also comes with important challenges and limitations. Understanding these factors early in the process can help you make a well-informed decision that aligns with your operational goals, safety standards, and budget.
Below are six essential things to consider before retrofitting your industrial heating equipment.
1. Careful Planning Is Essential
A successful retrofit begins with thorough planning. Evaluate whether the existing equipment can be retrofitted safely and efficiently, and confirm that the project will deliver the results you’re looking for.
Collaborate closely with qualified engineers and system designers to determine:
What modifications are required
The estimated cost and project timeline
Potential disruptions to plant operations
Compatibility with existing infrastructure
Taking the time to assess feasibility upfront can prevent costly surprises later in the process.
2. Understand and Comply With Code Requirements
Every industry has specific codes and safety standards that must be met when modifying or installing heating systems. These can include requirements for:
Pressure vessel design
Emissions and energy efficiency
Electrical and mechanical safety
Environmental regulations
If your retrofit plan is unconventional or involves custom components, it’s especially important to verify compliance before work begins. Noncompliance can lead to project delays, fines, or even system shutdowns.
3. Review Warranties and Service Agreements
Retrofitting can sometimes affect the original equipment warranty. Before proceeding, ask:
Will this work void existing warranties?
Who will warranty the retrofitted system?
What are the terms for service or maintenance after installation?
Clear answers to these questions will help you avoid unexpected costs or service gaps in the future.
4. Evaluate the Impact on Efficiency
One of the main goals of a retrofit is often to improve system efficiency. However, not all modifications result in performance gains—especially when equipment is repurposed for a new function.
Measure your system’s current efficiency and establish performance benchmarks before and after the retrofit. This data will help you evaluate whether the investment delivers the expected return.
5. Recognize That Retrofitting Isn’t Always Feasible
In some cases, retrofitting may simply not be possible. Physical space constraints, outdated designs, or incompatible materials can make upgrades impractical or unsafe.
If that’s the case, it may be more cost-effective to explore a new, customized heating system designed for your facility’s specific requirements.
6. Consider When a New System Might Be the Better Choice
Even if retrofitting is technically feasible, it might not be the best long-term solution. A new system may offer:
Higher energy efficiency
Improved reliability and safety
Lower maintenance costs
Advanced control and automation features
While the upfront investment is higher, new systems often provide greater value and performance over time—especially for facilities aiming to meet modern energy or sustainability goals.
Making the Right Choice for Your Facility
If your facility is considering a retrofit or complete system upgrade, it’s important to weigh all your options. Partnering with an experienced industrial heating equipment manufacturer can help you determine the best path forward.
At Enerquip, we’ve spent over 30 years helping facilities design, upgrade, and maintain efficient thermal fluid heating systems. Whether you’re evaluating a retrofit or exploring a new custom solution, our team can help you identify the most cost-effective and reliable option for your operation.
Comments Off on Why Routine Plant Operator Training is So Important
In industrial facilities, unexpected shutdowns can halt productivity, cause costly delays, and even pose safety risks. While equipment failure is sometimes to blame, operator error remains one of the most common causes of plant downtime. The good news? Consistent, high-quality operator training can dramatically reduce these risks.
Plant operators play a hands-on role in daily operations, directly influencing productivity, efficiency, and safety. When properly trained, they help ensure that systems run smoothly. When training is inconsistent or outdated, however, even small mistakes can lead to major disruptions.
This is why routine plant operator training is essential for any facility that depends on thermal process equipment.
Why Routine Training Matters
1. Preventing Unplanned Shutdowns
Human error is one of the leading causes of unexpected shutdowns. Regular training ensures your operators understand proper procedures and can identify and correct potential issues before they escalate. By keeping your team up-to-date, you minimize unplanned downtime and maintain steady productivity.
2. Promoting Workplace Safety
Safety is a top priority in any plant environment. Routine safety training helps employees recognize hazards, follow correct protocols, and react effectively in emergencies. In facilities that use thermal process equipment, safety training is especially vital to prevent burns, leaks, or equipment damage. A well-trained team is a safer team.
3. Improving Efficiency and Performance
Well-trained employees are not only safer—they’re faster and more effective. When operators fully understand their equipment and responsibilities, they complete tasks more efficiently and troubleshoot minor issues without delay. This not only saves time and resources but also enhances overall plant performance.
4. Preparing for Employee Turnover or Retirement
In many plants, veteran employees hold years of valuable knowledge. Regular training ensures that critical information doesn’t leave when they do. Cross-training multiple operators on key tasks keeps your operation resilient and prevents overreliance on a single individual.
Key Areas for Operator Training
Every facility has unique processes, but the following training categories apply to most:
General Equipment and Process Training
Operators should understand their day-to-day responsibilities, standard operating procedures, and available resources like equipment manuals and supervisor guidance. The goal is to make routine tasks second nature, reducing hesitation and mistakes.
Safety Training
Comprehensive safety education covers both prevention and response—teaching operators how to identify risks, use protective equipment properly, and handle hazardous materials or emergency shutdowns safely.
Maintenance and Inspection
Creating a maintenance-first culture starts with training. Teach operators how to recognize early signs of wear, perform basic upkeep, and follow reporting protocols. Proactive maintenance prevents costly breakdowns and extends equipment life.
Shutdown and Startup Procedures
Planned or unplanned, shutdowns require precision. Training employees on shutdown and startup sequences ensures smoother transitions, protects equipment, and minimizes production loss.
Troubleshooting and Problem Solving
Empower operators to quickly and safely identify and resolve minor issues. With the right training, they can restore systems to full operation faster—often without waiting for specialized technicians.
How Often Should You Train Plant Operators?
While every industry differs, annual training should be considered the bare minimum. Many facilities benefit from quarterly or biannual refresher courses, especially when new systems, technologies, or safety regulations are introduced.
Think of training as an investment, not an expense. The time and cost of regular training pale in comparison to the potential losses from accidents, inefficiency, or equipment failure.
Investing in Training Pays Off
Routine plant operator training helps you:
Prevent costly downtime
Improve operational efficiency
Protect employee safety
Strengthen your workforce continuity
When your operators are confident and competent, your facility runs more smoothly—and your bottom line benefits.
Keep Your Facility Running Strong
If your goal is to improve safety, efficiency, and reliability, start by investing in your team. Routine training equips your operators with the knowledge and confidence to handle complex systems and unexpected challenges. And when it comes to keeping your systems performing at their best, high-quality thermal equipment makes all the difference.
At Enerquip, we design and manufacture stock and custom thermal solutions right here in the USA. Built to your specifications and engineered for long-term reliability, our equipment supports safe, efficient, and consistent operations.
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