Case Study
Overview
High temperatures in many industrial manufacturing processes can lead to poor product quality and reduced output due to process slowdowns. Whether you’re producing high-performance rubber tires or weather-resistant shingles, BETE offers effective, efficient cooling systems that preserve material integrity, lower operating costs, and keep production moving.
High Temperatures Affecting Rubber Quality
At a leading tire manufacturing facility, elevated temperatures in freshly
extruded rubber were compromising product quality and throughput. In
peak ambient conditions, rubber compounds processed at temperatures
up to 380 °F (193 °C) retained excessive heat after exiting the forming
conveyor. This was causing:
• Quality inconsistency for varying line speeds
• Potential for material deformation and variability
• Forced process slowdowns to maintain cooling consistency
The customer sought a targeted spray cooling system to provide effective,
controllable heat reduction — from 380 °F (193 °C) down to 215 °F (102 °C) —
without oversaturating the rubber, which could lead to water runoff, and
increased risk of worker injury.
BETE Process Cooling System
BETE engineered a spray cooling system that integrates two custom
spray headers with Electric HydroPulse® (EHPI) automatic spray nozzles featuring BJ tips, paired with the FlexFlow® spray controller, to deliver precise, automated cooling. A live on-site demonstration validated the system’s ability to rapidly reduce material temperatures before the next
stage of processing, ensuring the preservation of the rubber’s quality even
in high-temperature ambient conditions.
Utilizing plant-supplied water pressure and eliminating the need for compressed air atomization, the system delivers operational simplicity and a potential cost savings of over $8,000 per year. The EHPI enables targeted, fine droplet spray patterns ideal for heat transfer efficiency, while the FlexFlow system provides closed-loop temperature-based feedback control for precision tuning under dynamic conditions.
BENEFITS OF BETE’S COOLING SYSTEMS:
- Reduce or eliminate the need for compressed air, lowering operating costs
- Provide droplet atomization tailored to your application for rapid heat transfer
- Deliver consistent, repeatable results with advanced yet intuitive controls and automation
- Integrate easily to minimize disruption to existing process lines
RESULTS
The new spray system effectively reduces the process temperature over 100 degrees without oversaturation, leading to more consistent product quality and safer working conditions. As a result of the positive outcome, the customer has ordered additional systems for production lines at their other facilities.
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