Customized processing systems with superheated steam (SHS)
Customized processing systems with superheated steam (SHS)
We implement customized system solutions for industrial applications that operate with superheated steam (SHS). In doing so, we implement a wide range of thermal processes, including drying, roasting, pasteurization, and torrefaction.
Advantages of SHS over hot air
Higher drying speed
Superheated steam (SHS) has a higher heat capacity and thermal conductivity than air. This enables faster heat transfer. Drying times are reduced by 20–50% compared to conventional hot air processes – at the same product temperature.
No oxidation on the product
Since the process takes place in the absence of oxygen, oxidation of your product is virtually impossible.
Low risk of fire or explosion
The risk of fire and explosion is largely eliminated due to the oxygen-free system.
No exhaust emissions
Typically, drying processes using hot air produce odorous exhaust air that must be cleaned and removed at great expense. With SHS, there is no exhaust air.
Fully electrifiable
If the steam is generated electrically, this improves your carbon footprint in your sustainability report and significantly reduces carbon costs in the long term.
The system can be fully electrified, but also allows other energy sources such as gas or hydrogen.
Lower energy consumption
Superheated steam has a lower density than air and can therefore flow through your product more easily.
During drying, the drying medium—in this case, superheated steam—cools down slightly. The remaining energy content can be fully utilized in an SHS drying system by simply reheating the steam. Air, on the other hand, would have to be dehumidified at additional expense before heating.
The moisture contained in the product evaporates during drying. In hot air systems, it is difficult to use the resulting humid air for energy purposes. With SHS, however, the additional steam produced can be used to operate other systems, returned to the system as superheated steam by means of mechanical vapor compression, or used as warm water through condensation.
Your company may generate excess steam elsewhere, the energy content of which can be utilized in an SHS drying system.
Utilize existing infrastructure
Many industrial companies already have the infrastructure for steam generation and distribution in place. This means that additional investments may only be necessary to a limited extent.
Recovery of volatile substances
You can easily recover volatile components of the product by condensing the vapor.
Heating, drying, roasting, and pasteurizing in one system
All process steps that take place under the influence of heat, including heating, drying, pasteurization, and roasting, can be carried out using superheated steam. With precise process knowledge, product humidification can also be achieved.
How does a SHS process work?
Water vapor is heated to over 100°C, creating superheated steam.
This superheated steam flows into a closed drying chamber where the product to be dried is exposed to the steam.
Through contact, the superheated steam extracts moisture from the product. As a result, the steam absorbs additional water and cools slightly.
The excess moisture is continuously and permanently removed from the system.
At the same time, the slightly cooled steam is reheated in a cycle process and returned to the system.
Which products are suitable?
Food
For example, croutons, nuts, seeds, vegetables, coffee beans, mushrooms, fruit pieces such as apple chips or banana slices, legumes, and much more.
Pet food
For example, dog food, cat food, treats, feed pellets, fish food, rodent food, and much more.
Pharmaceutical products
For example, active ingredient powders, tablet raw materials, excipients, granulates, pharmaceutical additives, and much more.
Mineral bulk materials
For example, mineral bulk materials, salts, sludge, sand, clay, and much more.
We can test the following parameters in a product test:
Our laboratory and pilot systems
Before placing an order—or even independently of this—our four laboratory and pilot systems are at your disposal. Whether short product tests (1–2 days), comprehensive trial studies (1–2 weeks), or joint research projects with universities: we will find out whether SHS is the right process for your product and how it can be dried optimally.
Reference projects
Mill dryer: Participation in the development and manufacture of a mill drying system
Batch Dryer: First in-house laboratory dryer, “Batch Dryer Non-Food,” which is continuously modified and adapted and is still used today in our technical center for customer trials.
SolChemStor: EU research project by Fraunhofer IGB on the storage of high-temperature solar energy
BioEcoSIM: SHS drying system for an EU research project by Fraunhofer IGB on the processing of manure into various fertilizers
HiPerDry: (Microwave-combined) SHS drying system for an EU research project by Fraunhofer IGB on the drying of plastic granulates
Screw dryer: Development of an SHS screw dryer
BioEcoSIM
HiPerDry
Screw Dryer
Belt dryer: Development and manufacture of a belt dryer as a pilot system for use in the beverage industry according to customer requirements
EnReMilk: Development and construction of an SHS spray dryer for the production of milk powder as part of an EU research project by Fraunhofer IGB
SmartDry: Fraunhofer IGB EU research project Development and construction of a belt dryer. The aim is to develop an intelligent control system for the dryer that enables the desired output moisture content of the product to be generated consistently, regardless of the input moisture content. Since the end of the project, the SmartDry belt dryer has been one of our technical center facilities, which we use to conduct product trials for customers.
Fluid Bed Dryer: Development and manufacture of an SHS jet layer dryer for drying foodstuffs – long-term cooperation with several institutes in accordance with customer requirements – now used as a fluidized bed dryer in our technical center
Belt dryer: Involvement in the development and manufacture of our first SHS belt dryer as a pilot project for drying pet food according to customer requirements.
Roaster: First prototype of the SHS coffee roaster with vibrating bed
PhosFarm: SHS drying system for an EU research project conducted by Fraunhofer IGB on the recovery of phosphorus from agricultural waste
GOBi: SHS drying system for recovering salts from fermentation residues as part of the Fraunhofer IGB's EU research project on optimizing biogas plants.
Tray Dryer: SHS trade fair dryer Heckmann/Fraunhofer IGB for the ANUGA trade fair
Tray Dryer
SteamBio: Fraunhofer IGB EU research project to develop an SHS drying machine for wood chips. The aim is to extract certain substances from the condensate produced, e.g. for the production of bioplastics.
Valorkon: EU research project of the Fraunhofer IGB for which we built an SHS drying system that torrefies wood and recovers volatile substances from the wood via condensate recovery, making them usable again.
Batch Dryer: Second in-house laboratory dryer, “Batch Dryer Food,” which is constantly being modified and adapted and is still used in our technical center for customer trials.
Batch Dryer
Since 2023: Establishment of our technical center in Rethem, Lower Saxony. Focus on direct industrial applications.
Reference projects
Belt Dryer
Involvement in the development and production of our first SHS belt dryer as a pilot plant for drying pet food according to customer requirements
Mill Dryer
Involvement in the development and manufacture of a mill-drying plant
Roaster
First prototype of the SHS coffee roaster with vibrating bed
Batch Dryer
First in-house laboratory dryer “Batch Dryer Non-Food”, which is constantly being modified and adapted and is still used today in our technical center for customer tests
Phosfarm
SHS drying plant for an EU research project by Fraunhofer IGB to recover phosphorus from agricultural waste
SolChemStore
Fraunhofer IGB's EU research project to store high-temperature solar energy
BioEcoSIM
SHS drying plant for an EU research project by Fraunhofer IGB to process manure into various fertilizers
HiPerDry
(combined with microwaves) SHS drying system for an EU research project by Fraunhofer IGB for drying plastic granules
Screw Dryer
Development of a SHS screw dryer
Gobi
SHS drying plant for the recovery of salts from fermentation residues as part of Fraunhofer IGB's EU research project to optimize biogas plants.
Tray Dryer
SHS trade fair dryer Heckmann/Fraunhofer IGB for the ANUGA trade fair
Belt Dryer
Development and production of a belt dryer as a pilot plant for use in the beverage industry according to customer requirements
EnReMilk
Development and construction of an SHS mixer for the production of milk powder as part of an EU research project by Fraunhofer IGB
Steambio
Fraunhofer IGB EU research project to develop an SHS drying machine for wood chips. The aim is to obtain certain ingredients from the resulting condensate, e.g. for the production of organic plastic.
Smart Dry
Fraunhofer IGB EU research project Development and construction of a belt dryer. The aim is to develop an intelligent control system for the dryer, which makes it possible to always generate the same desired initial humidity of the product regardless of the initial humidity of the product. Since the end of the project, the SmartDry, as a belt dryer, has been one of our pilot plants, with which we carry out product tests for customers.
Valorkon
EU research project by Fraunhofer IGB for which we built an SHS drying plant that torrefies wood and extracts volatile substances from the wood through condensate recovery and makes them reusable.
Batch Dryer
Second in-house laboratory dryer “Batch Dryer Food”, which is constantly being modified and adapted and is still used today in our technical center for customer tests.
Fluid Bed Dryer
Development and production of an SHS jet layer dryer for drying food — long-term cooperation with several institutes according to customer requirements — today as a fluidized bed dryer in our technical center
Technikum
Since 2023: Establishment of our technical center in Rethem, Lower Saxony. Focus on direct industrial applications
Hecki Coffee
Unlike conventional hot air methods, the patented roasting process developed by Hecki uses superheated steam.
This ensures that the coffee beans are roasted particularly gently and evenly – without coming into contact with oxygen. The process generates hardly any emissions and does not require complex exhaust gas purification.
The patented process involves circulating a roasting gas stream consisting of 70–90% superheated steam at a minimum temperature of 150°C through the beans – an innovative step forward for quality and the environment.
About Heckmann Group
The Heckmann Group is a family-run mechanical and plant engineering company. Since its foundation in 1974, it has developed into a medium-sized company with several locations. With around 550 employees, the group offers tailor-made solutions for various industries.
The Heckmann Group is a family-run mechanical and plant engineering company.
Since its foundation in 1974, it has developed into a medium-sized company with several locations.
With around 550 employees, the group offers tailor-made solutions for various industries.
known companies already place their trust in Heckmann
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This is how your project will proceed
Initial consultation
In an initial discussion, we will clarify your use case together and define the rough framework.
Tests
We conduct practical tests at our pilot plants to determine the optimal drying parameters for your product.
Process design & quotation
Based on your application, we will develop the appropriate process design and prepare a customized quote.
Construction
We take care of all electrical and mechanical engineering as well as design.
Manufacturing
We manufacture your drying plant mechanically and electrically.
Installation & commissioning
We take care of the safe transport, professional installation, and smooth commissioning of your system.
After Sales Service
We supply replacement and wear parts, perform maintenance and repairs—and can even do so remotely if desired.
André Nitzsche
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