A food ingredient manufacturer achieved full odor compliance and reduced fuel consumption by using Epcon’s low-temperature drying oven with an integrated catalytic thermal oxidizer (CTO). The system protects heat-sensitive products through gentle drying profiles (40°C – 120°C) while the CTO and integrated heat recovery ensure environmental compliance, eliminate community complaints, and significantly improve operational sustainability.
Food Ingredients – Low-Temperature Drying Oven with Odor Control and Energy Optimization
Executive Summary
Project Overview
A food ingredient manufacturer required a gentle drying system for heat-sensitive products where flavor, aroma, and functional properties must be preserved. The facility also faced community odor complaints linked to drying exhaust emissions and needed an effective, energy-efficient abatement approach without resorting to high-temperature oxidation.
Epcon engineered a low-temperature drying solution paired with catalytic oxidation and heat reuse to reduce both odors and operating costs.
Epcon engineered a low-temperature drying solution paired with catalytic oxidation and heat reuse to reduce both odors and operating costs.
The Challenge
The manufacturer needed to eliminate community odor complaints while maintaining food-grade product quality and controlling energy costs. They faced several issues:
- Food drying processes generate strong odors and VOC emissions (e.g., from natural extracts, seasonings, proteins) that require effective abatement.
- The heat-sensitive nature of the products demands low-temperature drying to preserve quality.
- Traditional high-temperature oxidizers are inefficient for low-temperature exhaust, leading to high, unnecessary fuel consumption.
- Odor control needed to be reliable at relatively low VOC concentrations and compatible with food manufacturing operations.
The Solution
Epcon delivered a low-temperature drying oven integrated with a catalytic thermal oxidizer (CTO) designed for odor abatement and VOC treatment at lower operating temperatures. The system includes heat recovery to preheat incoming dryer air, reducing net fuel usage while maintaining consistent drying performance.
Controls were designed to support repeatable product recipes and stable operation across varying production conditions.
Controls were designed to support repeatable product recipes and stable operation across varying production conditions.
Technical Specifications
Feature / Component | Specification / Benefit |
Oven Type | Low-Temperature Drying Oven (Food Ingredient Application) |
Operating Temp Range | 40°C – 120°C |
Emission Control | Catalytic Thermal Oxidizer (CTO) (Optimized for odor/low-temp VOC) |
Heat Recovery | Dryer Air Preheat (Reduces net fuel usage) |
Airflow Management | Controlled Circulation (Ensures Uniform Drying) |
Control System | PLC/HMI with Recipe Profiles (Repeatable process control) |
Operational Efficiency | Lower fuel consumption vs. traditional high-temperature oxidation |
The Results
“The CTO completely eliminated our odor complaints. We are compliant, the flavor profiles are protected, and the fuel savings are a bonus.”
The installed system delivered substantial benefits in quality, compliance, and cost:
The installed system delivered substantial benefits in quality, compliance, and cost:
- Product quality was preserved through gentle, precise drying profiles.
- Community odor complaints were effectively eliminated, securing compliance and reducing operational risk.
- Substantial fuel consumption reduction achieved through heat recovery and lower-temperature catalytic oxidation.
- Lower total operating cost compared to traditional high-temperature abatement approaches.
- Improved overall sustainability and reduced environmental footprint.
Industry
Applications
This advanced low-temperature drying system is essential for processors who must balance product integrity with strict environmental performance, including:
- Food Ingredient Manufacturing (Extracts, Seasonings)
- Nutraceutical and Pharmaceutical Drying
- Specialty Chemical Processing
- Any Low-Temperature Thermal Process Requiring Odor Abatement
Next Steps
Secure Odor Compliance and Protect Product Integrity
In food processing, you cannot compromise on flavor or compliance. Epcon’s low-temperature drying ovens and integrated CTO are engineered to eliminate community complaints and guarantee product quality while delivering cost-saving energy efficiency.
If your facility is facing odor complaints or needs an energy-efficient solution to protect heat-sensitive products, your next step is simple. Contact our thermal engineering team directly for a custom odor abatement analysis, or initiate a chat now to discuss your specific product profile and compliance needs.
In food processing, you cannot compromise on flavor or compliance. Epcon’s low-temperature drying ovens and integrated CTO are engineered to eliminate community complaints and guarantee product quality while delivering cost-saving energy efficiency.
If your facility is facing odor complaints or needs an energy-efficient solution to protect heat-sensitive products, your next step is simple. Contact our thermal engineering team directly for a custom odor abatement analysis, or initiate a chat now to discuss your specific product profile and compliance needs.
Contact Epcon for Custom Solutions
Epcon offers full engineering, fabrication, and installation of afterburner-based thermal oxidizers, quench systems, wet scrubbers, and full emissions-control lines — customized for chemical, petrochemical, and industrial gas-stream applications.If your facility handles acid gases, H₂S, solvent exhaust, or other challenging emissions, contact our engineering team to discuss a tailored solution.
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