|
Kiln theory and knowledge
|
|
|
|
|
Piggyback Pallet Kiln
Piggy-back unit installed on a container/van body.
|
First we need to be honest and say that any container-based solution is an inferior solution when compared to a "real" pallet kiln solution. However, for low volume usage the container based solution may often be the most economical choice. To provide our customers with the best solutions for low volume usage, Kiln-direct has launched a new Piggy-back unit to be installed on a container/van body.
|
Pallet kilns can be loaded using a standard forklift |
General air circulation in container-based pallet kiln.
Compare container based pallet kiln design.
|
| How does our Piggy-back unit compare? |
| |
Our Piggy-back Unit |
Main Competitor's
Standard System |
| Fully automatic control system. |
YES
 |
EXTRA COST
 |
Extra wood temp sensors.
3 is Standard |
YES, 3 extra.
|
NO extras.
 |
| Automatic recordkeeping. |
YES
Controls connected
directly to office computer. |
NO
Have to upload
and then print later. |
Recirculate air through heat system.
Lower gas consumption. |
YES
Less gas costs |
NO
More gas costs |
| Loading full height container. |
YES
|
YES
|
| Heat capacity. |
680000 btu/hr
But we waste less. |
800000 btu/hr
|
Extra fans inside for better
heat distribution. |
YES, all aluminum.
Complete fan header
with 2x2HP fans
to optimize air flow. |
YES, painted steel.
Two individual blowers
with less air flow. |
| On-site installation help. |
YES.
At minimum cost. |
NO.
Not common. |
| Price for complete system. |
$17500.
|
A bit lower, maybe.
|
Overall value from ordering to
long term operating costs. |
Lower gas consumption,
More temp sensors,
Better controls,
One large unit.
GOOD NEWS |
Higher gas consumption,
No extra sensors,
Basic controls,
Many parts.
WELL, YOU GET
WHAT YOU PAY FOR! |
|
|
The general problems of using an insulated container or van body for an HT kiln:
-
Container/Van body not made for high temperatures.
-
All insulated containers/van bodies are designed for storage and transport at colder temperatures. They are NOT designed for hot temperatures. This means that when you expose the kiln to 200F or higher over extended periods of time you cannot expect the chamber to last as long under high usage.
-
Good air circulation is not feasible.
-
The only practical loading pattern is using the full height of the van or container. However, this means that we cannot create a firm circular pattern as in our larger kilns which allows for good air circulation. Therefore, we have reversed the air flow and added a full-sized fan header which is located inbetween the loaded pallets. See the picture above.
-
Does not recirculate air through heat system (except ours).
-
Most container-based pallet kiln systems available on the market do not recirculate the air back through the heat system; however, ours do. Air that is not recirculated means that you will have less venting and more hot air escaping during the process which will increase gas usage and lead to higher treatment costs.
-
Not a full truck load capacity.
-
Since you have to load the pallets with the stringers in the direction of the air flow you can normally only load about 20-22 stacks of pallets, which is about 400-440 pallets per load. This means that in most cases you will need to run the kiln twice to heat treat a full load (560-630 pallets).
|
Picture Gallery of a
Piggy-Back Pallet HT Unit
for a Container-Based Kiln |
Piggy-back heating/controller unit.
Aluminum inside fan header
comes separate. |
 |
Piggy-back Pallet HT system
leaving on a truck to the customer.
In this case we will be helping
with the installation.
Or, you can come and
pick it up yourself. |
 |
Piggy-back heating/controller unit
installed on your container or van-body. |
 |
Fully automatic control system
with multiple safety systems
connected directly to your
office computer for easy record keeping.
We have 2 chamber and 6 wood temperature
sensors, which is double our
competitors' standard
to insure better operation. |
 |
A 680000 btu burner is
installed inside one of the side doors.
We recirculate the air from
the kiln chamber, thereby
reducing your gas costs. |
 |
Cutting openings
in the van-body. |
 |
Inside view of piggy-back unit
installed on van-body. |
 |
Main fan header placed
inside the load
after 6 rows of pallets. |
 |
Container-based pallet kiln
loaded and ready to be started. |
 |
Computer in the office linked
directly to kiln controls
for easier record keeping. |
 |
As mentioned earlier, we do not believe that the container-based heat treatment kiln solution is very good technically, but in cases with low volume it may be the most economical choice. We are very pleased to offer this new design that combines the most practical layout with a decent technical design. However, we do believe we offer the very best container design.
If you have any questions or need additional information, please do not hesitate to contact us by phone: (910) 259-9794.
We are looking forward to the opportunity of working with you and your company.
|
Kiln controllers, fans, sensors, vents, heat systems and more
