OVEN SELECTION

GUIDELINES
Environment Friendly Engineering Solution Company

In Association with SVCH-Technologii, Moscow (Russia)

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About Kerone

Mission
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centric
purpose machineries) . engineering solution.

KERONE is pioneer in application and implementation engineering with its vast

experience and team of professionals. KERONE is devoted to serve the industry to Industrial heating, drying and cooling segment, with strategic tie-up for the
-

Vision

”Enhance the value of customer operation through our ecological

customer need centric engineering solution”

engineering solution company.
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of rich Experience
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Purpose of this Guide Elementary Oven Consideration

The key motivation behind this guide is to talk over general concepts and issues re- Heating equipment are generally classified as oven and furnace, while ovens oper-
lated to the selection of industrial equipment for heat processing. ates around 1000oF on other hand furnace operates above 1000o, is this the only
difference between two categories? NO. There are lot more apart from this, just con-
Heat application has become necessary for all most for any type of product being tinue reading this guide you will get to know the real difference.
manufactured and processed, this guide was created to provide a base knowledge of
the intricacy of matters associated to selection of optimum equipment for any partic- Heat processers are designed based on loading methodology batch type or continu-
ular process. This guide is just for information please reach to Kerone’s engineering ous conveyor type. The source of heat can be combustion fuels such as gas, oil and
team for actual product design and implementation. etc., electric, steam or hot water depending upon desired process, material under
processing, desired outcomes.

Choose Carefully Heat Transfer Methods

Selecting heating system that best fit to your process requirement. based on type of Natural convention, forced convention and radiant heat transfer are few of the heat
applications such as curing, drying, heating, sterilization just few of them. Same de- transport techniques from heating source to material under treatment. Natural con-
sired outcome may require special attention, as the heat processing is varying widely vection heating usually turned out to be very speedy, but results are not uniform
from industry to industry even some occasions product under processing. heating which is advantages of forced convection. Both methods are flexible, control-
lable and can be focused for odd shapes. Radiant heat transfer is quicker at higher
You may wonder how same thermal transfer principle differs based on the product temperatures and primarily cost efficient, but is not as flexible as convection and
under process or manufacture. Below we have tried to describe few general criteria must be tailored specifically considering product requirement.
that requires your attention in order to make you general classification and basic
working principles. In accumulation to diverse varieties of transfer, heating equipment may be intended
to contain special atmospheres such as argon or nitrogen, or may include superior
manufacturing materials required for explicit needs.

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Making Right choice

Issues that can encounter while selecting right type industrial equipment, includes:

• Quality of material under processing – both before and after process

• The structure of material l uniformity, size and shape

• Feeding mechanism, manual or automated

• Type of firing mechanism desired

• Sensitivity of material towards heat

• Permissible tolerance level

Batch type may turn out to be the better choice for the processes those comprise of
chemical slurries, or there is huge difference in the input and output product size or
output fluctuates extensively.
On other hand continuous type of suitable of processing paints, heat treatment of
uniform material, food sterilisations, basically the places where the quantity is large
and but processing temperature and material are mostly same.

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Batch-Type Ovens
This category of oven encompasses of all the oven large to small those operates in
batches, which mean a predefined (limited) quality of materials are fed as input
(manually or mechanically) in oven cabinet and later the door is closed and it process
the material for set time period and later released.

These ovens are the largest category of ovens used to manufacture products in
batches. This can be classified as cabinet-style or truck-loaded type. The characteris-
tics of oven may change from size, feeding mechanism, construction and processing
time and temperature.

At Kerone, we offer batch type ovens for both laboratory and industrial applications.
Batch ovens range in capacity from 2 to 24 (only indicative) cubic feet. Typical tem-
perature ranges are from 80°F to 850°F.

Batch type ovens can be extensively used for curing, baking, drying, finishing, anneal-
ing, sterilizing, and etc; almost the applications are limitless.

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Continuous Ovens
This category of ovens includes all the type of ovens those operates in continuous
manner with the help to conveyor belts for feeding material and then transporting it
with in the oven and post processing taking it out of oven. No manual intervention re-
quired, sometimes have different temperature zones, no wastage of time, possible to
integrate with existing process/assembly line. Conveyorized ovens are capable of
handling large quantity of materials on continuous basis.

The type of conveyor designated for a continuous application depends completely

on the type of products being processed and their configuration at the time of pro-
cessing. Conveyorized ovens can be unitized for all type of application for those
batch was selected, such as:

Curing | Baking | Cooking | Preheating | Annealing | Sterilizing | Drying

Above application are just to name few, Kerone’s continuous conveyorized ovens can
be used for all type of heating application. However, it becomes economical it the
quality to be process are large.

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Heat-Up/Soak/Cool-Down Times
Heat-up, soak, and cool-down times are key components to give importance for choosing the precise oven. Below are the few basic questions that can be asked:

1. Does the oven have adequate heating ability to 2. Will the product be able to take up heat at a rate 3. Should the rate of increase of heat be controlled or
convey the product to the desired temperature within adequate to extent temperature within the definite all the product to reach the temperature in no-time?
the definite cycle time? time?

The answer to this question depends on the mass and The thermal conductivity of the material, the size and If the process does not want that the heat-up rate be
specific heat of the product. For example, the specific shape of the product, and the velocity and direction controlled, a standard set point controller may be
heat of material is 0.126 BTU/lb x degrees Fahrenheit. at which the air impinges the surface of the product used to control oven temperature. The oven load will
For 10000 pounds of material to touch 500°F from
are decisive factors for the rate at which a product reach temperature as rapidly as the product volume
50°F within an hour will require:
can absorb heat. and oven heating capabilities will allow, may not be
10000 pounds x (5000F-500F) x 0.126 BTU/lb x de-
grees Fahrenheit ÷ 1 hour = 56,7000 Btu/H in linearly.
This is the energy essential to heat the product. The Just estimating the heat absorption rates based on
heating capability of the oven should to be greater, charts and formulas even for common materials are If a controlled heat-up is required (e.g., heat-up at 1o
due to heat losses via the oven walls, via exhausted not sufficient, hence at Kerone research center we F per minute), a programmable, ramping controller is
air and via heating of the oven mass itself. In an oven conduct actual test on the materials to get to know needed. Such a controller allows a specific, linear
where the exhaust rate during heat up is 60 Standard the exact rate at which a product absorbs heat. heat-up rate to be programmed
Cubic Feet Per Minute (SCFM), the heat needed to
heat air will be:
The absorb rate should be in range otherwise, the
60 SCFM x (5000F-500F) x 1.1 Btu/H/SCFM 0F =
29,700 Btu/H product may not be able to reach the desired tem-
If the wall losses for the oven are 5000 Btu/H, the perature in the desired time frame, even though the
heater capacity will need to be at least: 56,7000 + heating capacity of the oven is sufficient.
29,700 + 5,000 = 60,1700Btu/H
Converting it in Kilo watts (1kw = 3412Btu/H)
60,1700Btu/H ÷ 3,412 Btu/kW-Hr = 176 kW.

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Soak Times Cool-Down Times

Soak time indicates to when the item has achieved the ideal process temperature for Since cooling can be thought of as expulsion of heat, product contemplations for
the desired time interval. A programmable controller can be customized to stay at cool-down rates are like those for heat-up rates. Ordinarily, broiler cool-down is ac-
temperature for a predetermined time-frame, at that point chill off to finish the cycle. complished by depleting heated air from the stove. A relating stream of cooler, sur-
For many applications, the soak cycle begins once the time determined for the rounding air will enter the stove to supplant the warm depleted air. In the event that
warm-up cycle has been finished. the cool-down rate requires no control, the main need is to estimate the fumes fan
sufficiently extensive to evacuate the essential measure of heat in the required time.
To make the control more precise, it is necessary to restrict the soak time until the
product temperature has reached, a Guaranteed Soak option can be utilized. In this Exhausting oven air can be achieved by the ways of:
method, the controller does not start timing the soak cycle until a thermocouple em-
bedded on the product, or in the air stream, senses that the set point temperature 1. Exhaust damper are kept open to the sufficient point, and suppling the heat from
has been reached. other end to maintain the temperature of oven.

2. Controlling the damper by the means of programmable controller is another

option. The dampers will be controlled in order to keep cooling rate maintained.

With passive atmosphere oven, howev-

er, cooling by means of exhausting
oven air is not usually a viable method,
as oxygen is introduced into the oven.
Air-to-air or air-to-water heat exchang-
ers are effective in removing heat from
the oven in these applications.

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9
Air-To-Air Heat Exchangers Uniform Temperature
These use a finned plate located between the oven air and a duct through which am-
bient air is drawn. By this means, heat is directed over the plate and unrestricted to Uniform temperature with in Oven or temperature uniformity is defined based on the
the ambient air. This type of exchanger is suitable for higher operating temperatures usage, processing type and type of oven. Uniformity is not maintaining same tem-
where the temperature difference between the oven air and ambient air is great perature across oven, but the basic definition states that uniform temperature varia-
enough for heat transfer to occur at a sufficient rate. tion within the oven based in the demand of process and type of oven. Commonly ex-
pressed in ± degree C or F at from reference temperature.

Maintaining uniform temperature across oven results in smooth processing and

Air-To-Water Heat Exchangers
better product quality. Oven temperature uniformity greatly affected by:
These are used at lower operating temperatures, typically 50°F above ambient. With
this type of exchanger, oven air passes over a finned, water-cooled coil. The cooling
rate is precisely controlled with a solenoid valve which regulates the flow of water Oven wall losses
into the coil. Remember, the coil size and flow should be designed to prevent water
from boiling in the coil.
Volume of airflow

Door openings

Control mechanism and accuracy

Air circulation

Physical construction techniques

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Wall Losses Air Flow

Ovens wall as made out of metals hence the temperature losses due to walls will be The airflow is key attribute in maintaining uniform temperature across the oven. The
if not insulated properly, hence to maintain the uniformity and minimise the losses, type of airflow (horizontal or vertical airflows), the volume of air being moved and the
it is required to pull down the metal losses to absolute minimum by properly insulat- reach up to all points within the oven are most important determining factors in tem-
ing the walls. perature uniformity.

The better the controlled air volume flows through an oven, better the uniformity can
Opening and closing doors be achieved. A fan and motor combination are properly sized to make the amount of
static pressure drop through the oven in order to achieve the desired uniformity. The
Ensure that oven openings for fresh air and exhaust are intentionally found. The area oven walls are lesser susceptible to losses at low temperature heating, hence main-
gives a positive weight differential (in connection to the outside of the oven), so cool taining uniformity become easy. Uniformity becomes matters of concern as the tem-
surrounding air brought into the oven through door seals is limited. The fresh air perature starts rising, it becomes hard to achieve the uniformity as it has higher wall
opening should in like manner be found so the fresh air can mix totally with the recir- losses hence need boosted insulation, requires higher airflow fans and motors and
culated air. carefully designed and controlled airflow circulation.

Kerone research and development center (KRDC) we perform various type of tests to
Air Circulation maintain uniformity that result in best quality output. Some of the type tests carried
out is
Also, the oven air stream ought to be planned so air going through the heating com-
ponents is sufficiently blended before entering the work chamber. On the off chance Thermocouple test:
that fresh air is inadequately blended with recycled air, air layers at various tempera- - Without input: Placing thermocouple in various corners of oven then raising the
tures, called air stratification, will influence oven uniformity. Air duct design, place- temperature from ambient to desired points and checking noting the results
ment and geometry also contribute to uniformity. - With material under processing: Material to be processed in placed under the oven
the re-performing the test.

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Loading and unloading Material
Material handling or material movement can be manual or automated based on type Few of the conveyor belt attributes might seems to be irrelevant to material handling
of ovens and material under processing. Inputting to and outputting material from many are not quoting them, but I assure you they all are connected to each other.
oven is very critical as it affects the processing time, speed of material movement and
also final product design. Inefficiently planned loading and unloading mechanism Monorail type conveyors, Pusher type conveyors, Roller conveyors powdered, chain
may turn out to be bottleneck in entire process. type conveyor, Screw conveyors are few other commonly used conveyors.

Material loading are mainly of two types batch loading also known as Truck loading, Monorail conveyors generally comprise of the chain and trolley system; they provide
the material handling in batch type of oven are usually simple, however before heavy duty application. Weight of material to carried, number of material per cabin,
points that needs to be taken care are: spacing between hook, type of hooks and fixtures, speed of conveyor motor, and pro-
• Total weight of the load cessing time within the oven are some of key points to be considered of consulted
• Number of units to be processing in every day with experts.
• Processing cycle time
• Number of processed outputs required per shift/day Sometimes special handling is required for the very delicate or hazardous materials,
please connect with Kerone to explore all available options
The other type of material handling/loading mechanism is continuous flow that uti-
lized belt type conveyors as means of moving products through an oven. Few
common but important attributes of the continuous material handling are:
• How product will be fit on conveyor
• Quantity that can travel
• Weight of material
• Length of Oven
• Speed of conveyor belt
• Processing time
• Temperature within oven

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Types of Airflow
As already discussed, airflow and its distribution within the oven is very critical in maintaining uniform temperature within the oven. Tests carried out in empty oven always gives
brilliant results with any airflow patterns, however in fully loaded oven the story is different. Load configuration plays vital role in selection of airflow patterns, the object in deciding
airflow pattern is to minimize the obstruction to flow and expose the maximum product surface area to air.
Few of the common and popular air circulation and distribution patterns are discussed, however it is advisable to connect with experts at Kerone.

Horizontal Airflow Uniflow Airflow

Hot air is supplied from one side and return Hot air fed from both the side as travels along
to the other end in-line with surface of oven. the walls and returns at the top, this is also
Commonly used in batch type ovens in which known as hybrid airflow control which as ad-
the material is loaded in trays or shelf that vantages of both vertical and horizontal air-
allows the air to flow through and through flow. It is best suited when the material/prod-
from both above and below material loaded. uct under processing is large and has com-
plex shape.

Vertical Airflow Reverse Airflow

Hot air is supplied either from top and return This is inverse version of uniflow airflow, here
from bottom or other way around, effective in this airflow mechanism hot are is supplied
for the materials that allows the passage of from top and reruns at the bottom side of
air vertically. This type of air flow is suitable both walls or opening and closing.
for both batch and continuous ovens where
material so placed or hanged such as way
maximum surface area is exposed to airflow.

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Oven Loading Heating Mechanism
Oven loading are vital part of the oven in order to choose the best suited configura- Heater firing mechanism becomes one of the critical selection factors as this plays
tion. Type of loading varies based on the product/material to be loaded for process- decisive part in energy consumption and energy utilization, which is a critical factor
ing. Few of the common loading mechanisms are: when processing the material and also for long run of the heater. Generally, electric
fire heating systems offers best efficiency almost close to 100%, when compared
1. Reach in front loading: Standard reach-in front loading are commonly used for the with gas / fuels fired heaters, however gas fired is less expensive when compared to
light-weight or easy to handle product. electric fired heaters. Direct fired gas heating is more efficient than indirect gas fired,
but efficiency is only dependent on the firing but also deviates a lot based in the
2. Walk in front loading: Walk-in front-loading ovens are used to handle heavy or temperature desired and ventilation requirements. Electric heaters are generally of-
hard to handle products. Usually size of the material/products are large, suited for fering better control also at low temperature and provides better temperature unifor-
truck loading applications. mities. Also, you can explore our new age heating techniques which uses IR, micro-
wave and RF.
3. Top Loading: Top loading ovens have entry of the product/material to be processed
from top opening of the ovens.

4. Drawer type loading: Few products are suitable of the drawer type of applications
Cooling Mechanism
as it helps in minimizing heat losses by carefully designing the drawer sizes.
Exhaust fans of proper size is only sufficient for cooling at lower temperature down

Oven loadings can be operated manually or powered to operate using electric or to 100°F. However, if your processing was at higher temperature or you require

pneumatic. Powered loading doors make the process more automated and level of higher cooling rate or have an passive atmosphere oven, then you can explore our

error are reduced. Kerone can help you with both manual and powered loading other cooling options such as:

doors. 1. Air- to-air

2. Air-to-water
3. Intermediate cooling chambers

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Ovens in hazardous conditions Electrical Power required
Ovens to be situated in special or hazardous conditions requires some exceptional You should know the electrical power that would be desired to operate your oven
design considerations. These ovens considerations are not only limited to within the and other machines beforehand, so you can access the gap between available to re-
oven chamber oven but also external atmosphere specifically for an explosion hazard quired power. You should know the voltage, number of phases available, total power
from the possible ignition of dust, vapours or gas. consumption. While planning for desired electrical power please take all your electri-
cal equipment in consideration and balance the loads accordingly.
While designing oven that has to operate in such scenarios, requires very careful plan-
ning and similar importance to both internal and external factors, such as: Local electric frequency and load should be given importance as some part of word
• Fans should not produce and spark on start and stop electrical frequency is 50Hz while for others its 60Hz. Mostly ovens are considered
• Properly insulated and sealed wiring and junction boxes to work on any electrical supply, however if several supplies are present, consider
• Motors must be of proper rating (motors should not get over loaded or produce spark) the following:
• Air circulation source of fresh air from and release air outside hazardous area a. Electrical motors are very common and important part of the oven. You should be
• Product loading and unloading should be automated to avoid any human error aware of power requirement of the motors being used.
• Stringent control mechanism for controlling with accuracy b. Three phase electrical supply is more suitable for industry scale ovens to operate
as the power requirement is high and if voltage is low, then current requirement
Since such environmental conditions are very critical for machine and man life, hence becomes high as (Power = Voltage x Current).
several classifications and design guidelines are suggested by NFPA as well. You should c. Large current will increase size of few component and will make the oven more
get the environment audited first in collaboration with Kerone to enable us to design expensive.
oven that is safe to operate for life time. d. Wire should be chosen with minimum losses and higher conductivity.
e. All the connections should be properly sealed and terminated.

Please check local requirements beforehand for various ratings.

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Process Control and Monitoring Electrical Power required
Accuracy of Sensor, performance of Control systems and construction of system are key You should know the electrical power that would be desired to operate your oven
contributors in process measurement and control. and other machines beforehand, so you can access the gap between available to re-
quired power. You should know the voltage, number of phases available, total power
Thermistor, RTD and Thermocouple are the most popular type of temperature sensors, consumption. While planning for desired electrical power please take all your electri-
however they are many varieties of sensors available in the market. Choosing a tem- cal equipment in consideration and balance the loads accordingly.
perature sensor for your application can be a critical task. Current market offers wide
range of sensors that you might feel lost sometime. Local electric frequency and load should be given importance as some part of word
electrical frequency is 50Hz while for others its 60Hz. Mostly ovens are considered
Modern day controllers are having in precise temperature controller with auto tuning to work on any electrical supply, however if several supplies are present, consider
PIDs. Controller performance depends on the accuracy of measurement, response time the following:
controlling units and effectiveness on the final processing. a. Electrical motors are very common and important part of the oven. You should be
aware of power requirement of the motors being used.
The structure or physical construction of the measured oven or furnace system has vast b. Three phase electrical supply is more suitable for industry scale ovens to operate
influence on the play-acting of the regulator system. On the off chance that the airflow as the power requirement is high and if voltage is low, then current requirement
supply is non-uniform, or cool air leaks exist in the process chamber, or the control point becomes high as (Power = Voltage x Current).
is inappropriately chosen, or the warmth source is mistakenly sized, the best control c. Large current will increase size of few component and will make the oven more
framework on the planet won't deliver agreeable outcomes. There is no hope to im- expensive.
prove the performance shy of improving the mechanical qualities of the framework, d. Wire should be chosen with minimum losses and higher conductivity.
which may not generally be conceivable. e. All the connections should be properly sealed and terminated.

Please check local requirements beforehand for various ratings.

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Processing Flammable Materials Oven Floorboards
NFPA (National Fire Protection Association) suggested various classes for the ovens Floorboards or the bottom surface of the oven too have vital roles to play in success
based on the materials to be processed and environment condition. NFPA classifies of overall oven performance, other environmental and available space consideration.
such ovens under “Class A”. There are ample choices available for the selection, however will all suite your re-
quirement? This is biggest question. Most of the ovens have a metal panel floorboard
Materials which are flammable, combustible or highly reactive needs special oven for surface mounting, other types are recessed into the factories existing floor, also
construction and design standard to be followed based in guidelines of NPFA. Class the surface mounted ovens with insulated cement are available.
A ovens are graded for extreme material handling capacity, usually specified in gal-
lons per hour of a specified material at specific temperature. Truck loaded ovens mostly preferred with an isolating surface with recessed track or
rails to guide the position of channels.
Kerone has dedicated team of SME (subject Matter experts) those are experienced
and qualified in handling critical and flammable materials. All ovens designed and NFPA 86 suggested insulated floorboard for temperatures above 150oC. Floorboards
built follows the NFPA rules and other regularities. corresponding to calcium silicate protecting sheet offers the essential protecting be-
longings while saving on installation by disregarding the necessity for pouring an iso-
lating cement floorboard.

If you are wondering why the floorboard has become matter of concern, then contact
our Kerone research and development from www.kerone.com , you will have clear
picture of this importance of floorboard with live examples.

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General Consideration of Oven Construction
The oven should be properly wrapped with suitable metals properly ionised (if re- Sealed doors are important for operation of oven key factors that affects the
quired), painted, insulated and accurately joined. A properly constructed oven will design/selection of type of door seal are desired atmospheric condition, size of
accommodate the range of operating temperature, environment of operation and opening, type of door and maximum temperature of operation. Oven with higher
type of material operated on. Some of common consideration for the oven construc- temperature uses ceramic with silicone or fiber glasses on the other hand low tem-
tion are steel exterior painted with scratch resistant paint, properly insulated wall to perature ovens silicone seals. Vertical lift doors with pneumatic locking cylinders for
avoid any heat loss, easy to read and easy operate control panels, the door system bigger oven openings as they are appropriate to use and easier to seal.
with adequate thermal extension and structural integrity to run the oven for desired
duration of time at required temperature. Passive atmosphere ovens require dis-
tinct construction techniques for ex-
Internal oven construction becomes vital when the material to be processed are cor- pansion since insides should be cease- Tongue and groove
expansion joint
rosive, radioactive or flammable in nature, to avoid any kind of contamination interior lessly welded. Recirculating High Effi-
of oven is fabricated with the stainless steel, even some time painted with suitable ciency Particulate Air Filters can be
chemical as well. shared with the best possible oven and
Reinforcing
process design to permit cutting edge
Several aspects (specially related to process) must to be taken into consideration for control. Experience and notoriety are
Inside and outside
design of oven construction: especially imperative on the off chance wall sheet metal

• Maximum temperature of the oven that you are keen on one of these
• Size of the work chamber "clean process" ovens.
• Number and type of expansion joints
• Temperature uniformity to be maintained Insulation
(may be layered with temperature
graded types)
• Fan size depending on process
• Door size and seals
• Breaker strips to get the uniformity desired
Sectional view of oven wall

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Other General Considerations Keep it safe
Apart from key oven design consideration some of the common or general facilities Safety is greatest concern when designing and operating oven. Oven are designed to
that is required such as: uninterrupted stable poser supply (3 phase would be pre- operate within specified temperature range, with specific parameter to process the
ferred), proper ventilation and source of fresh air, availability of drainage facility, particular type of material for defined time interval. Improper usage of oven may
properly pressurised fresh water supply. These factors are not key contributor in result in some serious damages such as Fire, explosion, casualty to operator injury or
oven design and operation with still they are necessary for successful operation of death; hence a proper demarcation should be written for all controls. A well-defined
oven. and easy to understand user guide may help operator to avoid any kind of fatal acci-
dents.

See It Before we built for you (testing and proving concept):

It’s always better to see the pilot version of your oven running with real material and
get all the desired tests done on final output, material under processing and on oven.
Visit to our research center (Kerone Research and Development Centre (KRDC).

At KRND our team will help you to stimulate the actual behaviour of oven and materi-
al. Hence, various permutation and combinations can be tried out to get the best
oven.

If you have any query o you are seeking for any help, please visit www.kerone.com or
write us at info@kerone.com

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Our Clients
 Kerone Engineering Solutions Limited

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