Ferrite Microwave Technologies Foam Drying System offers industrial production lines increased speed, capacity, and process control. This system is able to increase capacity up to 50%, reducing the time to market for new products. It efficiently applies clean microwave energy, used to rapidly heat and evaporate water that remains in cured foam.
Microwave Foam Drying System: Our Designs
Our systems patented design uniformly applies microwave energy without damaging the foam cell structure or overheating. As a result, line speeds increase as much as fifty percent over traditional suction-drum and RF drying systems yielding exceptional value in increased capacity.
The generator in the foam drying system produces up to 100 kW of power at a frequency of 915MHz. Near-instantaneous control of this power enables precise moisture management of the final product. Quality problems caused by variations in the foam process can be minimized using this flexible microwave processing system.
The unique characteristics of this system create an innovative tool for development of new products. The foam drying microwave system can accommodate wet foam up to 1.25 inches (31.75 mm) thick, and up to 46 inches (1168 mm) wide. Standard units generate 100 kW of microwave energy, capable of evaporating up to 260 lbs. (118 kg.) of water per hour. Consistent shrinkage from the uniform distribution of microwave energy ensures a predictable end product. Unique product characteristics such as density, water capacity, and swell can also be developed utilizing our foam drying system.
Advantages of Drying Foam with Microwaves
- All electric power, results in zero carbon emissions
- Shrinkage characteristics enable development of new products
- Increase line capacity over traditional suction drum and RF drying systems
- Near instantaneous control over output power allows precise moisture control
Modular Designs: Customization
The modular design of the foam drying microwave system allows for easy customization to fit specific customer needs. Standard units are available that meet requirements for most customers. Clamped covers down the length of the machine make accessibility easy. There are very few moving components, making for impressive reliability, as well as minimal downtime. Key replacement parts include the magnetron, conveyor belt, and drive components.
We can recommend spare part requirements to ensure minimal downtime. Allen-Bradley PLCs are standard on all foam drying systems. Remote diagnostic checks on the control system via internet or modem access, allow our service team to rapidly identify and fix any issues.
Based on the standard 100kW system, the following utilities requirements apply:
|480VAC, 3 Phase, 60Hz, 200A for generator|
|480VAC, 3 Phase, 60Hz, 150A for controls, fans, heaters, and drive|
|34 GPM (129 LPM) of water at 75° + 5°F (24° + 3°C)|
Foam Drying Microwave Systems: FAQs
To help you better understand our microwave foam drying system, we’ve compiled a list of frequently asked questions, with answers. If you find yourself curious beyond these questions, contact our support team for further discussion.
Does the system come with a warranty?
All systems include a warranty for one year. Service contracts, on-site repair and maintenance are also available for systems after the warranty expires.
Is it energy efficient?
Yes. The foam drying microwave system runs exclusively on electricity. The generator is approximately 85% efficient converting electrical energy into microwave energy, and virtually all microwave power is absorbed by the water in the foam. Additional power is required to power conveyor drives, fans, and air heaters.
What are some of its safety features?
Microwave choking tunnels at each end of the machine minimize microwave leakage and meet applicable government guidelines for worker safety and electrical interference. Each unit also features a fully interlocked handheld microwave leakage tester for verification.
For more information about our foam drying microwave systems, please contact our support team. We look forward to learning about your materials, current processes, and developing a solution to best fit your requirements.