What is Direct Steam Injection?
Direct Steam Injection (DSI) is a highly efficient method of heating liquids and slurries by injecting steam directly into the product stream. Unlike indirect heating methods, which rely on heat exchangers or coils to transfer heat, DSI allows for the immediate transfer of the steam’s energy directly into the product. This ensures fast, consistent heating with minimal heat loss and enhanced energy efficiency.
In a direct steam injection system, steam is introduced into the product using a steam injector or sparger. The steam condenses instantly upon contact, transferring both sensible and latent heat. This leads to rapid temperature increases and precise temperature control — crucial for industries that require consistent product quality and efficient processing.
How Direct Steam Injection Works
The steam injector introduces high-velocity steam into the product stream. As the steam mixes with the product, it condenses and releases heat. This results in:
- Instantaneous heating – Quick heating minimises processing times.
- Uniform temperature control – Steam is evenly distributed for consistent heating.
- Energy efficiency – Direct contact reduces heat loss, making the process more energy efficient.
Benefits of Direct Steam Injection
- Faster Heating – The direct contact method allows for rapid heat transfer and reduced processing time.
- Precise Temperature Control – Immediate and uniform heat distribution ensures consistent product temperatures.
- Increased Energy Efficiency – Direct heating reduces energy loss, improving overall efficiency.
- Compact Design – DSI systems take up less space than indirect heating setups.
- Improved Product Quality – Rapid and even heating prevents burning, over-processing, or texture loss.
Armfield Equipment Featuring Direct Steam Injection: FT174
The FT174 Modular Miniature Scale HTST/UHT Process System from Armfield is a state-of-the-art solution that utilises direct steam injection to deliver high-performance heating and processing capabilities. Designed for precise high-temperature short-time (HTST) and ultra-high-temperature (UHT) processing, the FT174 is ideal for research and development in the food, beverage, and pharmaceutical industries.
Key Features of the FT174:
- Flexible Flow Rates – Operates at flow rates between 10–60 LPH for UHT and up to 100 LPH for HTST to suit a wide range of process requirements.
- Modular Design – The system allows for quick and easy configuration based on specific process needs
- Indirect Heating Capability – Tubular, plate and scraped surface heat exchangers can be specified
- Direct Steam Injection Capability – Enables rapid heating and precise temperature control.
- PLC-Controlled with Touchscreen Interface – Provides real-time monitoring and process adjustments.
- Aseptic Processing and Homogenisation – Ensures product integrity and consistency.
- Easy Maintenance – Designed for straightforward cleaning and maintenance to minimise downtime.
- Integrated Cooling and Chilling – After heating, the product can be cooled or chilled to specific temperatures using a chilled water supply.
The FT174 offers a comprehensive solution for high-performance processing, making it ideal for product development and small-scale production. Its ability to combine direct steam injection with HTST/UHT processing ensures high product quality and efficiency.
Learn more about the FT174 here
Historical Perspective: Evolution and Significance of Direct Steam Injection
The concept of steam injection dates back to the early 20th century when steam was first used for industrial heating. Early systems relied on heat exchangers and jacketed vessels, which often resulted in uneven heating and high energy costs.
The breakthrough came with the development of direct steam injection technology, which allowed manufacturers to bypass heat exchangers and introduce steam directly into the product. This created a more efficient and effective heating process. Over time, technological improvements, including the development of high-performance steam injectors and spargers, have enhanced the precision and scalability of DSI systems.
Notable Examples of Direct Steam Injection in Key Industries
Food and Beverage Industry
Direct steam injection is widely used for pasteurisation, sterilisation, and cooking. It ensures fast, consistent heating without compromising flavour, texture, or nutritional value. Products such as dairy, soups, and sauces benefit from the rapid heating and precise temperature control offered by DSI.
Pharmaceutical Industry
The pharmaceutical sector relies on DSI for sterilisation and precise temperature regulation during drug production and formulation. The FT174’s ability to handle aseptic processing makes it an ideal choice for pharmaceutical applications.
Chemical Industry
Direct steam injection is used in the chemical industry to heat process fluids, accelerate reaction times, and maintain consistent product quality. The ability to adjust steam pressure and flow rates allows for high levels of process control.
Factors to Consider When Choosing a Direct Steam Injection System
- Flow Rates – The system should handle both low and high flow rates without causing steam hammer.
- Temperature Control – High-performance control valves ensure consistent heating.
- Product Compatibility – The system must be suitable for different product viscosities and process requirements.
- Steam Pressure – The steam pressure should match the process requirements to avoid cavitation or incomplete condensation.
Why Choose Armfield?
At Armfield, we have over 50 years of experience in designing and manufacturing industry-leading direct steam injection systems. The FT174 stands out due to its high-performance capabilities, ease of use, and adaptability for research and production.
Discover the Power of Direct Steam Injection with Armfield
Interested in enhancing your production efficiency with the FT174 Modular Miniature Scale HTST/UHT Process System? Contact Armfield today to learn more about how direct steam injection can benefit your business.
