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Heat Exchanger Helps Aloe Processor Improve Quality

Drawing on decades of thermal engineering experience, Enerquip was approached by a producer of pure aloe for medicinal and nutritional products to solve a critical cooling challenge. Operating in a tropical climate, the processor needed a reliable way to reduce bacterial growth, improve product quality, and extend shelf life—all while working within limited utility and staffing constraints.

This case study highlights how Enerquip engineered a custom heat exchanger that delivered consistent, low-temperature cooling and long-term operational value.

The Processing Challenge

The aloe was harvested and packaged in a region where ambient temperatures regularly hovered around 95°F (35°C). These conditions accelerated bacterial growth during processing, which reduced shelf life and lowered the overall value of the finished product.

Through testing, the processor determined that cooling the aloe to below 40°F (4.4°C) prior to packaging resulted in a significant improvement in quality. However, achieving that temperature presented several challenges:

  • Cooling water was not cold enough to meet process requirements

  • Utilities at the packaging site were limited to electricity only

  • Plant operators were not highly technical

  • Production occurred only a few times per season

  • Equipment needed to be easy to clean, move, and store

Enerquip was asked to design a solution that addressed all of these constraints without adding unnecessary complexity.

The Enerquip Solution: Shell and Tube Heat Exchanger with Integrated Chiller

After reviewing the process and existing equipment, Enerquip’s thermal engineering team determined that a shell and tube heat exchanger would be the most effective and practical solution.

Heat exchangers are designed to efficiently transfer heat from one medium to another and are commonly used in sanitary and industrial manufacturing. They consist of a bundle of tubes enclosed within a larger shell. In this application:

  • The aloe product flowed through the tubes

  • A cooling medium circulated around the tubes inside the shell

  • Heat transferred through the tube walls without the fluids mixing

Several design factors influenced the final selection:

  • Viscous nature of the aloe product

  • Required inlet and outlet temperatures

  • Product flow rate and batch size

  • Ease of cleaning and sanitation

  • Seasonal operation and storage requirements

To meet these needs, Enerquip designed a straight-tube, multi-pass shell and tube heat exchanger. This configuration allowed the aloe to pass back and forth through the exchanger multiple times, achieving the desired cooling before packaging. Removable bonnets were incorporated to allow for fast mechanical cleaning.

Adding a Chiller to Achieve Target Temperatures

Due to groundwater temperature limitations at the facility, Enerquip integrated an air-cooled chiller into the system. The chiller supplied a glycol-water mixture cold enough to cool the aloe to target temperatures in a single pass through the heat exchanger.

Key benefits of the chiller system included:

  • Operation using plant electricity only

  • Simple push-button controls for ease of use

  • Minimal operator training required

  • Independent shut-off valves and removable hoses

  • Easy teardown, cleaning, and off-season storage

This approach ensured reliable cooling performance without increasing operational burden on plant staff.

Results and Impact

The completed system delivered measurable improvements for the aloe processor:

  • Significantly reduced bacterial growth

  • Improved product quality and consistency

  • Extended shelf life

  • Simplified operation for non-technical staff

  • Efficient cleaning between production runs

  • Increased overall product value

By combining a properly engineered heat exchanger with a chiller designed for the site’s limitations, Enerquip provided a durable, easy-to-use solution tailored to the processor’s real-world needs.

Ready to Solve Your Process Cooling Challenge?

Whether you’re working with viscous products, limited utilities, or demanding sanitary requirements, Enerquip designs a variety of stock and custom heat exchangers.

Contact us today to discuss your application and performance goals.

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