Heat exchangers for the process industry

A technology for manufacturing energy-efficient plate heat exchangers for the chemical, pharmaceutical, biotech, and food industries has been developed by Hubl Edelstahltechnik. Through precise stainless steel manufacturing and guided fluid flow, impressive heat transfer performance can be achieved with coordinated flow rates. And this with frequency-controlled energy supply and direct temperature control.

"Thanks to a new approach and our experience in stainless steel processing, we can produce significantly more energy-efficient heat exchangers for process technology," emphasizes Thomas Stek, Sales Manager at Hubl Edelstahltechnik. "With coordinated flow rates and targeted energy demand, we have almost doubled the heat transfer performance from 308 W to 610 W through numerous measures." Uniform and optimized cross-sections ensure significantly less pressure loss in the fluid circuit. This allows the required energy to be regulated much more effectively. It reduces the pump power needed and saves considerable energy. Similarly, the required flow rate of the medium decreases, depending on the size and volume of the heat exchanger, for example from 40 to 20 liters, halving it. This also results in substantial energy and cost savings. In operation, these numerous optimizations enable the heat exchanger to respond much faster to temperature changes.

Sustainable energy efficiency in cooling and heating

The energy-efficient heat exchangers for applications in the chemical, pharmaceutical, biotech, solar, and food industries can be used for both cooling and heating. They are used to cool medications just as much as to keep chocolate warm and flowable for further processing. The product-contacting inner plates can deliver the desired temperature very quickly, directly, and evenly to the contents. As cooling/heating media, both a water-glycol mixture and pure silicone oil can be used. However, significantly less energy is required compared to comparable heat exchangers.

The secret lies in design and manufacturing. Hubl Edelstahltechnik achieves efficiency gains through a novel construction and precise manufacturing technology with significantly lower tolerances. The carrier media are no longer just filled into a cavity but are forcibly guided through a meander-shaped labyrinth. The stainless steel or aluminum sheets used are formed using a tool-bound process. Stek explains the advantages: "Compared to laser-welded and inflated cavities, we achieve greater process safety and thus greater dimensional stability with better reproducibility." Tolerances of 1.5% compared to the previous 8-10% demonstrate increased manufacturing precision. Thinner sheets can be used, which improves heat transfer and additionally reduces material costs.

The secret lies in design and manufacturing

The base sheets can be made as thin as the guide sheets for the media. This allows the desired temperature to be reached, controlled quickly, directly, and evenly. Any concerns about stability are dispelled by Hubl Edelstahltechnik experts with a pressure test including certification. The heat exchangers are also suitable for use in cleanrooms, providing cost advantages to operators by halving cooling times.

The company can produce the new type of heat exchanger in many variants and sizes. Users can choose from square to round, small to large, with capacities ranging from 50 to 3000 liters. Hubl manufactures both prototypes and series products.

Cleanroom certificates for superior product quality

Thanks to state-of-the-art design and manufacturing processes based on many years of experience with stainless steel, Hubl impresses its customers. The sheet metal processor from Vaihingen/Enz places great emphasis on investments in production, making it a central part of the company with nearly 100% in-house manufacturing depth. In addition, the highest requirements are placed on the processing machines. An excellent machine park ensures that constructive solutions also result in excellent products. Working with the often V2A and V4A stainless steel types 1.4301, 1.4016, 1.4404, and 1.4571 requires extensive experience and often special procedures to cut, shape, or polish them to ensure cleanroom quality.

As early as 2010, the stainless steel specialist Hubl received cleanroom certificates from the Fraunhofer Institute IPA in Stuttgart for two series products. With these, the first sheet metal processor to be awarded quality seals, Hubl Edelstahltechnik offers products for use in the chip and pharmaceutical industries that meet GMP, FDA, and EHEDG requirements.

Stainless steel technology in perfection

Hubl Edelstahltechnik, an independent company of INEX solutions, offers excellent solutions in stainless steel in collaboration with Sommer & Strassburger – specializing in the healthcare, semiconductor, food & beverage, as well as energy & environmental sectors.

As a system supplier, Hubl provides its customers with complex development and design services and produces high-precision machine covers, frames, enclosures, and components made of stainless steel in the high-end sector. Hubl is often involved consultatively in its customers' processes to find tailored solutions.

The focus of the sheet metal specialists is on custom-made and small series in batch sizes of 500 to 2,000 units. Due to its flexibility and creativity, Hubl is a sought-after partner for both prototype and small series production as well as for series manufacturing. Quick, straightforward solutions for series parts are addressed just as competently as comprehensive support and advice in developing complex systems.

The portfolio is rounded off by a wide range of additional services such as
– Value-added analysis to optimize existing stainless steel products
– Cooperation with industrial designers already in the planning phase of projects
– Detailed documentation of all workflows
– Analyses and proofs of all kinds, such as FEM analysis, GMP proof, etc.
– Pressure equipment directives PED and ASME
– Cleanroom assembly

The scope of services also includes the integration of sensitive control technology, pneumatics, hydraulics, and mechanical components at the sensitive interface with the sheet metal. Also included are final commissioning, packaging, and shipping.

Depending on the customer's requirements, qualified employees form project teams that approach new tasks with commitment and enthusiasm. A healthy mix of "seasoned experts" and "new blood" guarantees solid knowledge and new ideas. Pioneering production technology, state-of-the-art computer programs, team performance, and intuitive gut feeling are the recipe for success at Hubl Edelstahltechnik.

With comprehensive expertise in product development, industrial design, and manufacturing-related design, as well as their production implementation, the company with around 150 employees generates an annual turnover of nearly 30 million euros.

Worldwide, hidden champions and renowned customers from demanding industries appreciate the reliability and performance strength of Hubl stainless steel specialists.