Summary
INTEK Corporation has partnered with a multinational biotech company to develop a state-of-the-art custom electric convection oven. Designed to provide precise thermal management and robust performance in demanding environments, the oven meets rigorous specifications tailored to maintain parts at specific temperatures while accommodating versatile processing needs.
Specifications and Engineering Parameters
Core Specifications
- Temperature Control Range:
- Operational: 50°C (122°F) to 300°C (572°F)
- Maintenance zone: 150°C (302°F) to 180°C (356°F)
- Maximum Temperature:
- 300°C (572°F)
- Interior Dimensions:
- 42″ Wide x 26.5″ Deep x 54″ Height
- Exterior Dimensions:
- Approximately 54″ Wide x 36″ Deep x 78″ Height
Electrical and Control Specifications
- Connected Load:
- 16kW heater load, compatible with 480V/3ph 60Hz systems, with 20A supply.
- Control Panel Components:
- UL 508A listed enclosure, 5kW SCCR rating
- Integrated Watlow F4T process controller and temperature control systems
- High limit controls, SSR, temperature cycle alarm, and inverter for blower control
Structural and Material Specifications
- Framework:
- High-grade structural steel ensuring robust assembly.
- Wall Materials:
- 20ga aluminized steel (interior) and 20ga galvanized steel (exterior).
- Insulation:
- 4″ industrial grade mineral wool ensuring thermal efficiency and safety.
Manufacturing Details
- Design & Structural Components
- Heating & Temperature Control
- Control Systems and Electrical Components
- Rack System
- Compatible Industries
Design and Structural Components
- Robust Structural Framework: The oven features a heavy-duty structural steel framework ensuring longevity and stability in industrial settings.
- Exterior and Interior Panels:
- Interior Walls: 20-gauge aluminized steel, providing excellent heat reflection and durability.
- Exterior Walls: 20-gauge galvanized steel, ensuring resistance to corrosion and external impacts.
- Insulation:
- 4″ of industrial-grade mineral wool insulation guarantees efficient thermal retention and energy efficiency.
- Double Front Doors:
- Designed for ease of loading and unloading, enhancing operator safety and operational efficiency.
Heating and Temperature Control
- Heater Capacity:
- Total connected load of 16kW, operating on 480V/3ph 60Hz with a dedicated 20A circuit.
- Temperature Range:
- Standard operational range from 50°C (122°F) to 300°C (572°F) with a dedicated maintenance zone between 150°C (302°F) and 180°C (356°F).
- Air Flow and Circulation:
- Cross airflow achieved via a recirculation fan, with air distributed through strategically placed perforations in the side walls and floor.
Control Systems and Electrical Components
- Control Panel:
- Pre-wired, fully tested, and designed as an independent unit.
- UL 508A Listed Panel: Type 1 enclosure with a 5kW SCCR rating.
- Integration of Watlow temperature control systems:
- Watlow F4T Process Controller
- Watlow temperature control integrated with a heater on-off switch
- Safety and Automation:
- High limit control, temperature cycle alarm, and solid-state relay (SSR) integrated into the system.
- Auxiliary Components:
- Functional inverter (Invertek VFD) dedicated to the recirculation blower.
Rack System
- Industrial Removable Rack:
- Features one adjustable height shelf, ensuring flexibility and ease of use during operation. (Note: The design was updated from a portable to a removable rack.)
Compatible Industries
The Stand Up Oven is engineered for a diverse range of industries, including but not limited to:
- Biotech & Pharmaceuticals:
- Thermal processing and sterilization applications.
- Medical Device Manufacturing:
- Precise heat treatments for component integrity.
- Aerospace & Defense:
- Curing processes and material conditioning.
- Automotive:
- Heat treatments and composite curing.
- Electronics:
- Solder reflow and thermal testing processes.
Assembly and Quality Control Steps
Assembly Process
Component Fabrication
Fabrication of the steel framework, interior, and exterior panels.
Insulation Application
Installation of mineral wool insulation ensuring uniform thickness and adherence.
Integration of Heating Elements
Assembly of the 16kW heater unit and secure electrical connections.
Control Panel Assembly
Pre-wiring and integration of the UL-listed control panel, including Watlow and Invertek systems.
Rack Installation
Installation of the industrial removable rack with adjustable shelving.
Final Structural Assembly
Assembly of the double doors and secure fitting of all components.
Quality Control Steps
- Material Inspection:
- Verification of steel, insulation, and panel material quality prior to assembly.
- Pre-Assembly Testing:
- Functionality tests on the control panel and electrical components.
- Dimensional Accuracy:
- Detailed measurements to ensure interior and exterior dimensions meet design specifications.
- Thermal Performance Testing:
- Oven is subjected to a controlled heating cycle to verify temperature control range and stability.
- Safety Compliance:
- Final inspection to ensure adherence to UL 508A and other industrial safety standards.
- Final System Audit:
- Comprehensive quality audit before shipping, ensuring all engineering parameters and operational tests are met.
Conclusion
The custom electric convection oven developed for the multinational biotech company exemplifies INTEK Corporation’s commitment to engineering excellence and innovation. With robust manufacturing practices, strict quality control procedures, and detailed attention to engineering parameters, the Stand Up Oven is poised to serve demanding industrial applications across multiple sectors. This case study underscores the synergy between advanced design, quality manufacturing, and precise engineering, ensuring reliable, safe, and efficient thermal processing in a variety of competitive industries.