Duct separator – New air cleaner for the food industry prevents blockages

Air cleaner for the food industry in the processing of chocolate, cocoa, oils and fats.

Duct separators and air cleaner for the food industry
Duct separators and air cleaner for the food industry

In the food industry, duct separators are used in the processing of chocolate, cocoa, oils and fats to extract these substances. In many processes in the food industry, these substances have to be both heated and finely atomized. Only then can chocolate, cocoa, oils and fats be processed meaningfully and, for example, be applied to a carrier material.

Heated chocolate during processing
Heated chocolate during processing

The problem with this: In addition to dust and water vapor, these processing processes also emit oils and other aerosols. These very finely atomized and often very hot substances must not get into the environment under any circumstances, as they would lead to a very high air pollution, so these substances must be extracted and separated from the exhaust air flow after extraction. So-called duct separators are used for this in the exhaust duct.

Exhaust air cleaning with a duct separator at Ferrero
Exhaust air cleaning with a duct separator at Ferrero

However, off-the-shelf scrubbers and air filters common in the food industry have poor filter performance. There are always blockages that interrupt the operation. The filter performance can be improved with a downstream electrostatic filter. However, electrostats are very sensitive to interference and cause high operating costs. The high humidity often leads to short circuits. The combination of air washer and electrostatic filter should therefore be assessed critically. The often used thermal post-combustion (TPC) has also often not proven itself for economic reasons. It requires high investments and the operating costs are also considerable. Companies in the food industry have a lot of waste heat anyway, so an additional heat generator like a TPC makes little sense.

Are there alternatives?

As an alternative to air cleaning in the food industry, we recommend a special duct separator that works according to the patented X-CYCLONE® process.

The X-CYCLONE® air purifier separator principle
The X-CYCLONE® air cleaner separator principle
X-CYCLONE® element separating oil and grease aerosols in food industry process
X-CYCLONE® element separating oil and grease aerosols in food industry process

It is also equipped with a spray device that wets all surfaces with a film of water. The unwanted particles are washed out of the exhaust air to a high degree and then ejected in the X-CYCLONE® separator by rapid deflections.

The X-CYCLONE® system with additional REVEX® spraying

Due to the high air velocity in the X-CYCLONE® element, on the one hand a higher degree of separation is achieved and on the other hand the mass transfer between exhaust air and wash water is strongly promoted, which leads to better cleaning performance of the separator. This is a very positive effect, for example when cleaning the air from fat, oil and chocolate aerosols! Since such substances can be sprayed with heated water, which successfully prevents these substances from hardening and sticking.

The combination works purely mechanically and practically cleans itself. This system technology almost achieves the efficiency of an electrostatic precipitator and only takes up a third of the area of a conventional air washer.

Duct separator with X-CYCLONE separator and REVEX spraying
Duct separator with X-CYCLONE separator and REVEX spraying

Typical areas of application for such an air purifier in the food industry are processes:

  • where cocoa beans are ground
  • where chocolates and ice cream are refined with a chocolate coating
  • where bread is cut and portioned industrially
  • where food products are industrially deep fried
  • where industrial baking takes place
Separated oil from an industrial backing process

The technical data for the duct separators presented here can be found here:

https://www.reven.de/duct_separator