How to Optimize, Control & Monitor your Process Remotely?








Every customer has specific equipment design requirements, and those requirements significantly affect the process control demands. Therefore, our control systems are highly flexible and adjustable to meet customers’ specific needs. Although designs vary from system to system, the following facts are standard for our control systems: highest accuracy, minimal delays, friendly, easy-to-use user interface, and safety as the priority.

The primary function of all Ovens and Furnaces is temperature precision. That is why we use several thermocouples at different places in the Ovens and Furnaces to detect the temperature inside the heating equipment, to ensure uniformity across all sections. The accomplishment of uniform temperature distribution in the Oven or Furnace is indeed an art that combines science and engineering. We successfully design systems for the most stringent operating parameters, where all sections of the unit are within 5 °F range.

As part of the engineering and system design process, Epcon’s team determines the appropriate number of re-circulating and exhaust fans with dampers, and vacuum ports, along with their size and positioning based on the processing unit’s required capacity and operating parameters, with details provided by the customer. The RPM of each fan and dampers’ percentage openings are automatically adjusted to meet the set criteria, enable constant airflow, and maintain the processing unit’s set pressure. The complex programmed control algorithm secures the optimized process at all times with the highest feasible thermal efficiency.

In addition, Epcon installs flow sensors throughout the air and gas process stream within the industrial process. The highest accuracy actuator automatically regulates air’s and gas’ flow based on user demand. Our custom programmed algorithm enables users to enter their target oxygen percentage directly, and the actuator will adjust the flows accordingly. Another manipulative variable that users may adapt in real-time is natural gas pressure since our PLC panel enables the compressors’ control based on the pressure transmitter response.

Most industrial boiler manufacturers utilize Siegert’s Formula as the combustion efficiency model to express the natural gas combustion process’s quality and take that value as the relevant one for the whole heating process. The issue with this model is that it is not 100% accurate as it only involves the temperature of air combustion and stack temperature besides the natural gas quality coefficient. The boundary-value of thermal efficiency that every Oven and Furnace must reach is 90%. The thermal efficiency calculation that we utilize includes the highly accurate temperature-dependent specific heat capacities of the materials that are heated. Therefore, all heat losses, even the minor ones such as ones by radiation and the loss in the insulation layer, are accounted for in the model we use. Before transportation of the equipment to customers, our team performs the final testing to ensure your equipment operations are as efficient as possible and operates exactly as designed.

Epcon Industrial Systems provides custom-designed Allen Bradley ContolLogix Programmable Logic Controller (PLC) with Panel-view plus that includes the following:

  1. HMI Rockwell Factory Talk View Site Edition Station Unlimited Display
  2. 120 V digital output modules for controlling all manipulative variables
  3. 120 V digital input modules for signals monitoring
  4. Analog input modules 
  5. Thermocouple modules
  6. 10% of spare I/O points for eventual further additions of the control system
  7. Software with graphic display

For cases of abrupt loss of power supply, we provide the uninterruptible back up power source for the 120V control circuit to operate PLC and operator interface for 60 minutes. The UPS represents a real online model with field-replaceable maintenance-free batteries.

The PLC is connected to an HMI Rockwell Factory Talk View Site Edition Station Unlimited Display. Epcon team installs and verifies the HMI software functionality on the customer-provided computer during the heating unit installation. A user-friendly interface allows the operator to define 25 cycle descriptions and several key operating steps within the process.

The issue with entering operating parameters manually between sessions is that it leaves space for human error. Still, more importantly, it causes delays in process’ stages. For example, if the operator needs 10 seconds to enter the new parameters between process stages and the process possesses 12 different stages, the result is 2 minutes, where the system does not run according to design, which is unacceptable in modern industrial production.

Usage of the digital input and output model enables minimal delays in transferring information in both ways, to and from the software. Another great advantage of the digital modules is that the process data is permanently stored. Data acquisition software is provided for customer-defined operating parameters. In that way, besides real-time monitoring, users can analyze the process at any point in the past time.

Another key function of the systems controls is safety and hazard prevention. We ensure all our equipment meets strict OSHA operating standards by programming a system shut down immediately if one of the following requirements is fulfilled:

  1. Oven or Furnaces door open with inner temperature over 150°F (Door switch)
  2. Heating units over-temperature state
  3. Heating/Recirculation chamber over-temperature condition
  4. Loss of airflow of each fan (airflow switch)
  5. PLC failure   

Additional requirements are considered according to process specifications, however these basic safety measures are built into every Process Heating unit that Epcon delivers.

When designing a control system, it is a priority to include features that allow operators to monitor system accuracy, and make real-time adjustments, while guaranteeing basic safety and hazard prevention.

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Improve your Process Heating Equipment Design by an Experienced Industrial Oven & Furnace Company

Throughout industrial manufacturing processes in general, industrial Ovens and Furnaces are the most commonly used equipment. They serve a wide variety of purposes such as drying, burn-off, curing, annealing, pre-heating, heat treating, and the list continues. The different types, sizes and configurations of industrial oven and furnace designs varies based on the required application and operating parameters.  While there many industrial equipment suppliers available in the market, only handful have the right engineering capabilities along with onsite manufacturing to provide optimized custom equipment. From concept to completion; all systems are designed, manufactured, and tested under one roof.

Choosing an experienced company ensures that you have the level of expertise as well as right technology to handle projects of any size, as well as complexity. For over 40 years Epcon has been custom engineering, designing and manufacturing a wide variety of industrial Ovens and Furnaces across industries and applications. It’s critical to combine technical competence with the resources available to meet the performance and profit objectives of the end user.

With each system designed to meet the customer’s specific process requirements, and with the majority of our business being repeat business, Epcon has a long list of happy and satisfied customers.

Our engineers work closely with our customer’s production and engineering team to develop the perfect system tailored to your unique process. Every production line is different, and understanding the customized needs allows us to fully optimize the Ovens and Furnaces; many of our systems also save the customer money by capturing and recycling the thermal energy in the process stream for other uses in the overall system.

At Epcon, a wide range of engineering services utilize the latest thermal dynamics modeling and 3-D rendering programs to test and model the equipment design to ensure the system is engineered to exceed our customer’s operating requirement.

The technical staff at Epcon not only has in-depth knowledge but also an expertise about the industries they are serving. This profound knowledge helps customer make the right decisions from the beginning of the project. Epcon’s engineers utilize technically advanced software, ensuring the custom design for each system is not only accurate, but will perform successfully for years to come.

Contact us today to see how we can help you meet your operational goals!

How can you enhance the Productivity of your Industrial Oven or Furnace?

Epcon Industrial Systems specializes in custom designing and manufacturing of Process Heating Equipment, including Industrial Ovens and furnaces of varying sizes and capacities to suit a wide range of applications include aging, sterilization, drying, tempering, annealing, and more. Based on your requirement, Epcon can customize your industrial Oven or Furnace to increase productivity, improve quality and stay within your budget with cost-effective solutions.

Epcon also provides Air Pollution Control Equipment, such as Thermal Oxidizers:  Recuperative, Regenerative, Catalytic and Direct Fired Thermal Oxidizers, as well as Specialty and Finishing Systems.

Epcon Industrial Systems provides you with a team of experts who have the cutting-edge knowledge to provide you with innovative solutions at the most affordable price. Our team includes leading industry experts from across various fields who will work with the customer to find the perfect custom solutions for the specific process and operation. We not only specialize in custom engineering and design, but also fabricate and test all industrial equipment at our on-site 250,000 square foot modern manufacturing plant to ensure 100% quality control and on-time delivery.

The technical team of Epcon Industrial Systems includes experienced Mechanical and Chemical Engineers who have an in-depth knowledge of not only respective industrial products, but about the industry as well. This amalgamation of knowledge helps our team to assist a wide variety of project applications from concept to completion. Epcon utilizes advanced software including process flow simulations and 3D modeling to design the required systems for accuracy and to ensures that your business operations are optimized and the most cost effective. Our team of engineers is equipped to provide you the best solutions for your business operations and needs.

Over the last 40 plus years, Epcon has served almost every industry, including Aluminum, A/C manufacturing, Aerospace, Ammunitions, Automotive, Chemical and Petrochemical, , Coil Coating,and the list continues. We pride ourselves in being an innovative leader across industries.

Epcon is also a one-stop-solution for rental equipment, service and maintenance, spare parts, rebuilds and retrofits. Prior to leaving the factory, all equipment is fully inspected and backed by our team of experienced technical staff. When you work with Epcon, we guarantee to ensure you have complete peace of mind for the operating life of your equipment.  Contact Epcon today for quotes!

Season’s Greetings from Epcon

Happy Holidays from your Friends at Epcon! We are so grateful to all of our loyal Customers and Industry Partners for such a wonderful year. Thank you for letting us serve you and keep your Oven and Furnace fires burning bright and Process Air as Pure as Snow!


Epcon Industrial Systems featured in Modern Metals

Epcon Designs And Builds Large Capacity Recuperative Thermal Oxidizer

October 27, 2020 – Epcon, Conroe, Texas, designed and built this large capacity Recuperative Thermal Oxidizer for a 55-gallon steel drum manufacturing operation. This system consists of Recuperative Oxidizer with primary and secondary heat recovery and stainless steel insulated ductwork to and from various ovens and sources of emissions. The entire system was built, shipped in components, installed, and commissioned by Epcon personnel. This is another feather in Epcon’s hat for a repeat customer.