In this 2-part mini-blog series we’re going to talk about the Hot Water System for a Snack Food Manufacturer
The Snak King Corp., in City of Industry, CA, is one of the largest snack food manufacturers on the West Coast. Since 2004, the company has been remodeling, reorganizing and upgrading its 177,000 sq. ft. kosher and organic certified manufacturing plant.
Snak King Corp. has an industry reputation for being an innovative manufacturer and marketer of unique and creative snack food products. Over the years, the company has received many industry awards, including the 2006 Snack Manufacturer of the Year. Their line of products includes: tortilla chips, extruded snacks, corn snacks, popcorn, caramel corn, nuts and pork rinds. Their brands include: El Sabroso, Granny Goose, Jensen’s Orchard and private label.
Snak King recently leveraged its innovative spirit in the implementation of a new hot-water system for production processing. The system used two banks of tankless water heaters to replace its previous system. Here is Snak King’s story and the background to their hot water innovation.
In October 2004, torrential rains pounded Southern California and crippled the Snak King’s manufacturing plant for 3 weeks. As it happened, the rain had weakened a 12,000 sq. ft. section of the roof, which collapsed directly over the heart of the plant. Although the roof collapse struck at the heart of the plant and disrupted operation, it did not crush the spirit of this gritty, entrepreneurial company lead by chair- man and CEO Barry Levin.
While the roof collapse left a scar on the company, Levin and his team discovered an opportunity to rebuild the plant and invest in new flooring and equipment.
The primary goal of the rebuild project was to enhance efficiency, consistency and capacity of the plant while continuing to meet increasing consumer demands.
As the project progressed, process engineers evaluated the capacity of the existing hot-water system and determined that it would not be adequate to handle an increase in capacity. Therefore, the engineers began researching options for replacing the system.
The engineers contacted Richard Ponce, a veteran in the tankless water heater industry, who has experience working in many commercial and residential projects.
Ponce began compiling information relative to the application and evaluating Snak King’s goals for the rebuilding project. He also considered the future capacity increase goals. Ponce proposed the following hot-water system.
Snak King Corp.’s manufacturing plant hot water demand load requirement: 120 gpm with long-term plant capacity increases to 165 gpm for up to 4-hour intervals; 7,200 to 9,900 gallons per hour (gph).
Snak King Corp.’s hot-water system design operating temperature: 120°F; temperature rise: 65°F.
Other relative hot-water system criteria:
- endless hot water supply
- limited available space
- energy efficiency required
- redundancy needed
- serviceability without any down time
- capacity expandability of the hot water system
- cost-effective solution
Based on the above criteria, Ponce proposed specifying for this application a multi-unit system of 28 WaiWela PH-28COF outdoor commercial tankless water heaters, manufactured by Paloma Industries. WaiWela, which is pronounced “Vi-vela,” means hot water in the Hawaiian language. The WaiWela PH28-COF tankless water heater is rated with an input of 199,900 BTU/hr., so the 28-unit system could modulate from the minimum input of a single unit, just 19,000 BTU/hr., up to 5.6 million BTU/hr. with all heaters firing. With each unit capable of continuously producing 5.2 gpm hot water at the 120 setpoint, the system is capable of continuously producing 145.6 gpm, or 8,736 gph.
(For more, see Part 2: Specifying a Hot Water System for a Snack Food Manufacturer, coming soon)