What is a Mixing Valve?

A mixing valve is a mechanical device that controls fluid temperature, commonly water, lube oil, or hydraulic fluid, by blending hot and cold fluids to provide a consistent output temperature. They are crucial in various industrial, aerospace, and defense systems where precise fluid temperature control is necessary.

This article provides an overview of mixing valves: types of valves, how they work, and applications for use.

Types of Mixing Valves

Two primary categories are motorized and thermostatic mixing valves.

Motorized mixing valves, also known as motorized or electronically controlled valves, use an electric actuator or motor to adjust the position of the valve’s internal components. This motorized adjustment allows precise control over the hot and cold fluid ratio, which regulates the outlet temperature.

Motorized mixing valves are often controlled electronically through a dedicated controller and are commonly used in commercial and industrial settings where accuracy is paramount. They are frequently used in applications requiring integration with automation systems, such as large-scale HVAC (heating, ventilation, and air conditioning) systems.

Thermostatic mixing valves use a thermal element, such as a wax-based cartridge, to adjust the mixing valve automatically based on fluid temperature. The thermal element expands or contracts in response to temperature fluctuations, which regulates the flow to maintain a consistent output temperature.

Thermostatic mixing valves are self-actuating and do not require external power to operate. They are commonly used in engines, compressors, lubrication oil cooling systems, hydrostatic drive circuits, radiators, and hydraulic power units (HPUs).

The primary difference between these types of mixing valves is the control method. Motorized valves use electric actuators and electronic control systems, while thermostatic valves rely on self-operating thermal elements.

How Does a Mixing Valve Work?

A mixing valve usually has three inlet connections: one for hot flow, one for cold flow, and one for the mixed fluid outlet. The 3-way control valve modulates between the hot and cold inlet feeds (ports “B” and “C”) to mix your fluid to the desired specified temperature exiting the “A” port.

The mixing valve would ensure the fluid remains within the optimal temperature range, preventing overheating or excessive cooling. Such temperature extremes could result in system malfunctions or damage.

When temperatures surpass recommended limits, fluid viscosity decreases, leading to issues like poor lubrication, seal degradation due to thermal stress, and even occurrences of pump cavitation or failure, conversely, fluid viscosity increases when temperatures fall below the recommended range, causing undue stress on internal components due to insufficient lubrication.

Mixing hot and cold fluids in controlled proportions helps maintain consistent temperatures, ensuring efficient operation and longevity of components.

Do I Need a Mixing Valve?

Mixing valves ensure uniform temperatures, prevent overheating, and enhance process efficiency, making them indispensable components in various applications in manufacturing plants, chemical processing facilities, and other industrial facilities.

Without the intervention of mixing valves, fluctuations in temperature could lead to detrimental outcomes such as component degradation, equipment malfunction, and even safety hazards.

Diverting Valve vs. Mixing Valve: What is the Difference?

A Diverting Valve controls flow between multiple outlets or pathways and directs it to different system components.

Diverting valve

A Mixing Valve controls fluid temperature by blending hot and cold fluids to achieve a consistent and safe output temperature.

Mixing valve

The primary distinction between mixing and diverting valves lies in their purpose: fluid temperature control vs. fluid routing. ThermOmegaTech offers a valve that can be used for mixing and diverting based on your application.

The flow direction of a port determines what makes it either a Mixing valve or a Diverting valve. For mixing applications, the valve will have two flow inlets and one outlet; in diverting applications, there is one inlet and two outlets.

Conclusion

In conclusion, mixing valves play a critical role in various industrial applications. They offer precise control over fluid temperatures and thereby enhance overall process efficiency.

Mixing valves’ versatility allows them to be applied in multiple settings, from large-scale industrial plants to smaller commercial systems. Whether regulating the temperature of water in a heating system, controlling the flow of coolant in an engine, or managing the temperature of hydraulic fluid in an HPU, mixing valves are essential in optimizing performance and ensuring reliability.

At ThermOmegaTech, we understand the importance of precise temperature control in industrial processes. That’s why we offer valves tailored to your or your customers’ needs.

Contact us today to discuss your temperature control needs, and let our expertise contribute to optimizing your operations with our compact, self-actuating valves.

Freeze Protection Case Study: Bridge Over Frozen Waters

Ware Shoals, South Carolina, has been plagued in recent winters by expensive repairs caused by freezing pipes. One particular application, a two-inch line mounted on the Marion P. Carnell Bridge over the Saluta River, was especially troublesome. As a result, pipes were constantly being repaired, and water flow was interrupted to hydrants and a hydroelectric station.

The Opportunity

Eastern Industrial Supplies, Inc. had the solution. Jack Sullivan, Eastern’s senior product manager for steam products, recommended ThermOmegaTech freeze protection valves.

“Ware Shoals is my hometown,” said Mr. Sullivan. “Helping the city is much more than a business relationship. So, I was thrilled to introduce a technology to help them solve a problem. ThermOmegaTech freeze protection valves were the perfect answer to lower costs and improve city infrastructure operations.” See how they did it here!

The Installation of Freeze Protection Valves

freeze protection valve

Three HAT/FP valves were installed on the bridge to automate purging water from pipes before they could freeze.

The valves are set at 35°F to open reliably and without electricity or human interaction when water reaches a freezing point, which is critical to city operations and residents.

“We were very interested when Eastern Industrial Supplies suggested they have a solution, especially one made with stainless steel and didn’t require electricity or batteries,” said John Lake, owner of L&L Environmental, which manages maintenance operations for Ware Shoals.

“The water line on the Marion P. Carnell Bridge used to be compromised every time we had a cold snap,” said Jordan Gambrell, wastewater supervisor at L&L Environmental.

“The freeze protection valves held up, with no issues, the entire winter. When you are on call 365 days a year, it is reassuring to know I can sleep at night knowing those lines won’t blow when it gets cold,” he said.

The damage caused by freezing pipes isn’t just water under the bridge.

Eastern Industrial Supplies and L&L Environmental can use ThermOmegaTech freeze protection valves to ensure water reliably flows under a bridge to equipment critical to the city’s operations.

Watch the video

About ThermOmegaTech

ThermOmegaTech freeze protection valves have proven to be both reliable and versatile. When the company was founded in 1983, they were initially used to protect locomotive engines. The ability to protect equipment worth hundreds of thousands of dollars has given maintenance supervisors confidence to apply ThermOmegaTech freeze protection valves in several critical Industrial applications. For example, condensate returns, docks/ports, pumps, safety showers/eye wash stations, and water supply lines for livestock all benefit from thermostatic balancing valves. Contact us here.

About Eastern Industrial Supplies Inc.

Eastern Industrial Supplies, Inc., headquartered in Greenville, SC, opened in 1980 and has expanded into markets across NC, SC, FL, GA, TN, and AL. While Eastern specializes in the quality distribution of pipe, valves, fittings, commercial plumbing components, corrosion corrosion-resistant products, and engineered specialty items, the company’s primary goal is creating a caring culture where people are always more important than profits. Eastern is also a proud member of Affiliated Distributors and an owner-member of SupplyForce.

 

In the News: Freeze Protection Feature Highlighted in Plant Engineering Magazine

Maintaining water-bearing equipment in a facility can be tricky, especially in wintertime. Ensuring piping, safety showers, condensate systems, and pumps are kept from freezing conditions is challenging. When these systems are exposed to freezing temperatures, they become vulnerable to damage and water supply disruptions, which can cause hazardous working conditions.

Freeze protection is critical in applications such as:

  • piping, valves, and fittings
  • pumps
  • filtration systems
  • holding tanks
  • condensate systems
  • fire lines
  • freeze-sensitive equipment
  • backup protection on traced systems/equipment

A common misconception is that your system will continue functioning when water is at freezing temperatures as long as the water is ‘moving,’ which is untrue. Water expands and freezes at 32°F, regardless of flow rate, and pipes can burst.

Which Freeze Protection Works Best for Your Facility?

Factors to consider are the location of the machinery, temperature variations, the presence of outdoor or exposed sections, and the criticality of the water supply. Assessing your facility’s specific machinery and water systems is vital to determining the most appropriate freeze protection methods. Different areas of your facility may require different strategies or multiple approaches. The severity of the winter climate should also be considered.

Various ways to Protect Water Lines:

Pipe Insulation: Pipe insulation is a commonly used method to help protect pipes from freezing. It is done by wrapping the pipes with insulating material, such as foam or fiberglass, to provide a barrier against the cold. Insulation reduces heat transfer and helps maintain a more stable temperature within the pipes. This is good practice but is not always enough protection to prevent freezing in extreme weather conditions.

Electric Heat Tracing: This process installs electric heating cables along the length of the pipes. These cables generate heat that keeps the pipes warm, preventing freezing. This method can be costly and vulnerable to power outages.

Pipe Taping: Pipe taping involves wrapping the pipes with specially designed heat tape or heating cables, generating heat to keep them warm. It is suitable for smaller pipes or localized freezing areas.

Pipe-Heating Cable Systems: Pipe-heating cable systems require electricity to function and consist of versatile, self-regulating cables that automatically adjust their heat output based on the surrounding temperature. The cables are installed directly on the pipes and provide constant heat to alleviate freezing. In extremely cold conditions, pipe-heating cable systems could struggle to keep up with the demand for heat, especially if the system is not designed for extremely low temperatures.

Backup Generators: In the case of power outages, backup generators can provide additional protection for freeze-prone areas. They ensure that essential equipment, such as heat tracing systems or pipe-heating cables, continues functioning even during power failures.

Space Heaters: Heating the air around the pipes with space heaters can provide temporary freeze protection. This method is suitable for small, localized areas or temporary setups.

Manual Valves: These valves provide a means to control water flow in a piping system. They are manually operated, allowing users to open, close, or partially restrict the water flow.

Thermostatic Freeze Protection Valves: Freeze protection valves are specialized valves that prevent freezing in piping systems. These valves automatically open when the temperature drops below a certain set point, allowing a controlled water flow to prevent freezing. When the temperature rises, the valves close.

Low temperatures can turn worst-case scenarios into reality without adequate protection. Upholding diligent maintenance and awareness during cold weather can avert expensive and inconvenient repercussions from frozen pipes. Even heat-traced systems risk freezing in the event of an electric tracing malfunction.

Once freeze protection is in place, facility maintenance personnel have a better chance of working safely and protecting their equipment from freeze damage.

 

ThermOmegaTech Freeze Protection Valves

Freeze Protection has three (of many) applications: a condensate manifold, a float trap, and safety showers/eyewash stations.

 

 

 

 

 

 

 

Utilizing Temperature-sensing Freeze Protection

Manual valves are an easy solution for freeze protection to implement, but you introduce the risk of human error (forgetting to turn the valves on or off). Opting for a self-actuating, non-electric freeze protection method can offer superior protection for your water systems compared to other techniques.

Thermostatic freeze protection valves prevent water from freezing within pipes and systems by monitoring temperatures and adjusting flow. Utilizing thermal actuator technology, they sense the water or air temperature and will open to bleed off the cold water until it reaches a safe level. Because the valve functions without power, it is ideal for explosion-proof and remote areas.

Freeze protection valves are particularly useful in intermittent water flow or when power is not readily available for heat tracing systems. They are widely used in industrial settings such as oil refineries, chemical terminals, and processing facilities to forestall freezing within their systems.

Your Freeze Protection Solution

Water line thermostatic freeze protection HAT/FP valves from ThermOmegaTech use a specifically designed thermostatic wax actuator technology with an “install it and forget it” approach, simplifying freeze protection management.

ThermOmegaTech’s HAT/FP valve allows flow when the thermostatic actuator senses 35°F (1.7°C) and will remain open as long as the discharge water temperature is below 40°F (4.4°C). Installed in the standard flow direction, the actuator senses the ambient temperature and opens to initiate flow, then responds to water temperature.

Installed in the reverse flow direction, the wax actuator will always sense and respond to the water temperature to control the flow. Once the water temperature is above the freeze danger zone, the valve will modulate closed to conserve water.

The main benefit is cost savings; once installed, they require no additional power source and only activate when the water temperature is near freezing. Thermostatic freeze protection valves operate independently and reliably. They help prevent frozen piping with your facility’s systems and offer the convenience of a low-maintenance, long-lasting solution, protecting against freeze damage for all your applications.

“If systems are left unprotected, damage in piping can occur, so safeguarding your machinery with freeze protection valves offers a sense of security, knowing your systems are protected and won’t freeze due to unpredictable weather or a sudden cold snap,” explains Tim McCollum, ThermOmegaTech® OEM Sales Manager.

Questions on how to make your plant or facility safer? Contact ThermOmegaTech here.

Feature written by Marketing Coordinator Christine Tarlecki and it originally ran on March 24, 2024 on Plant Engineering. Read the full feature here.

Guide to Water Pipe Freeze Protection

Water pipe freeze protection is essential in industries such as food processing and manufacturing, chemical and petrochemical, oil and gas, construction, and agriculture to protect equipment during cold weather.

If water-bearing equipment is unprotected, freezing temperatures can cause burst piping, property damage, and water supply disruptions. A common misconception is that the system will continue functioning when water is at freezing temperatures as long as the water is ‘moving,’ which is untrue. Water expands and freezes at 32°F, regardless of flow rate, which can cause pipes to burst.

Water Pipe Freeze Protection - Frozen Pipes Image

The first step is to assess your facility’s water-bearing systems and determine the most suitable ways to protect water lines from freeze damage.

Some factors to consider are the machinery’s location and the water supply’s criticality.

Equipment that requires freeze protection includes:

  • Piping, valves, and fittings
  • Pumps
  • Filtration systems
  • Holding tanks
  • Condensate systems
  • Fire lines
  • Safety showers and eyewash stations
  • Solar collectors and piping
  • Water lines in farm equipment

It is also wise to have backup protection on heat-traced systems and equipment.

There are various ways to protect water lines from freeze damage. Pipe insulation, electric heat tracing, pipe taping, pipe-heating cable systems, backup generators, space heaters, and freeze protection valves.

What Are Freeze Protection Valves?

Freeze protection valves regulate water flow when the surrounding temperature drops to prevent water from freezing in pipes and systems. Valves typically fall into two categories – manual and automatic.

Manual valves require operators to manually adjust the valve open or closed to initiate or restrict water flow. These valves are an easy solution for freeze protection but have the risk of human error and forgetting to turn the valves on or off, which can cause severe damage or increased water usage.

Thermostatic valves are another option for protecting your systems. These valves are self-actuating and non-electric, preventing water from freezing within pipes and systems by monitoring temperatures and automatically adjusting flow.

How Does a Freeze Protection Valve Work?

Our HAT/FP thermostatic valves sense the water or air temperature and will open to bleed off the cold water until it reaches a safe level. The core technology in these valves is the thermostatic wax actuator. This actuator is sensitive to changes in temperature and can initiate actions based on temperature thresholds.

The valve is typically set to a specific temperature, often 35°F (1.6°C). When the thermostatic actuator senses the temperature is nearing this threshold, it initiates water flow to prevent freezing. Flow is maintained if the discharge water temperature remains below a certain level, typically 40°F (4.4°C).

By automatically initiating flow when temperatures approach the freezing point, the valves help maintain the integrity of the water system and ensure that water continues to flow without the risk of freezing. The valves will close to minimize water waste once the water temperature reaches safe levels.

Because the valve functions without power, it is ideal for explosion-proof and remote areas. They can protect your water systems more effectively than manual balancing and guard against human error.

The flexibility in flow orientation allows them to be adapted to various applications. The freeze protection valve is designed to provide a long service life, ensuring that it remains operational and reliable for an extended period. This longevity reduces maintenance and replacement requirements.

Protect Your Facility with ThermOmegaTech Freeze Protection Valves

Freeze protection valves

ThermOmegaTech’s water line freeze protection valves operate with a proprietary thermostatic wax actuator to protect your resupply lines against freezing. They operate independently to provide water pipe freeze protection and offer the convenience of a low-maintenance, long-lasting solution.

Stop asking yourself, How Do I Keep My Water Pipes from Freezing? The “install it and forget it” approach of the HAT/FP valve simplifies the management of freeze protection. Once the valve is installed, it requires minimal ongoing attention, making it user-friendly.

Another benefit is cost savings; it requires no additional power source and only activates when the water temperature is near freezing, significantly reducing water waste.

Start with ThermOmegaTech and protect your water-bearing systems.

Contact us here.

In the News: Plant Safety Feature Highlighted in Plant Engineering Magazine

Five Ways To Ensure Plant Safety in Processing Facilities

Processing facilities must ensure employees are trained and educated on proper protocols and procedures to maintain a safe working environment. Plant managers should regularly access the facility for risks and ensure sanitization procedures are followed.

Proper employee training and education

Employees are the backbone of any plant, and their knowledge and adherence to safety protocols are crucial. All-inclusive training programs should educate employees on proper hygiene practices, personal protective equipment (PPE) use and equipment handling.

“Regular refresher courses and ongoing education initiatives will help reinforce safety protocols and keep employees informed about the latest processing industry standards,” said Glenn Quinty, senior design engineer at ThermOmegaTech.

Assess facility risks

Conducting a thorough risk assessment is necessary to identify and understand potential hazards within the plant. This assessment involves analyzing the processes, machinery, chemicals and work environments to pinpoint possible sources of danger. Once identified, appropriate control measures can be implemented to mitigate risks and minimize the likelihood of accidents.

Develop proper sanitization procedures

Cleaning and sanitizing chemical, pharmaceutical, food and beverage processing equipment is critical to maintaining hygiene and operational efficiency. These facilities can offer microscopic places for germs and pathogens to hide, especially in cracks and scratches.

Effective sanitization practices should include regularly cleaning and disinfecting all surfaces and equipment. Washdown stations are a part of those best practices. Plant safety

“Using a washdown unit like ThermOmegaTech’s STVM Station that combines steam and water to provide a high-temperature wash has several benefits. Steam and water mixing stations provide instantaneous steam-heated water with pressure behind it, which can kill bacteria, sterilize and break down greases and other residues in processing plants,” Quinty said.

“When factoring in the amount of volume that the steam occupies in the pipe, as it is compressible, it allows more energy transfer per pipeline distribution size than water or electricity. This washdown station sanitizes equipment efficiently and prevents contamination while complying with industry standards,” he said.

Implement emergency safety equipment

Installing emergency equipment to protect personnel is vital to workplace safety. Occupational Safety and Health Administration (OSHA) regulations address the need for emergency eyewash and shower stations in 1910.151(c) but does not go into specific requirements for the equipment. The American National Standards Institute (ANSI) Z358.1 standard is the widely accepted guideline for adequately selecting, installing, operating, and maintaining emergency showers, eyewashes, eye/face washes and combination units.

ANZI Z358.1 addresses where and how to install the equipment and the flushing liquid’s velocity, pressure and temperature. If a person is exposed to a dangerous substance, they need to flush the area of their body exposed with tepid water as quickly as possible. Using tepid water prevents scalding and low-temperature shock.

There are various solutions for tepid water delivery to these stations, including mixing valves, electric water heaters and instantaneous electric or steam heater systems.

Strict adherence to regulations and industry standards

Adhering to relevant safety regulations and industry standards is non-negotiable. Compliance with legal requirements ensures that the plant operates within established parameters. Regular audits and inspections should be conducted to verify compliance and identify improvement areas.

Maintaining and enforcing employee training and education initiatives, assessing facility risks, following proper sanitization procedures and implementing emergency safety equipment are all ways to ensure your employees are at their safest while working daily.

Questions on how to make your plant or facility safer? Contact ThermOmegaTech here.

 

This article ran on January 18, 2024, in Plant Engineering magazine. Read the full feature here.

 

 

ThermOmegaTech® Announces New NSF/ANSI 61 Certification for Pump Thermal Relief Valves

ThermOmegaTech® is excited to announce its pump thermal relief valves’ NSF/ANSI 61 certification. NSF/ANSI 61 and 372 is an American National Standard that establishes minimum health-effects requirements for the chemical contaminants and impurities indirectly imparted to drinking water from products, components, and materials used in drinking water systems.

ThermOmegaTech’s ECONO/HAT-RA is a thermal relief valve designed to safeguard domestic water supply booster pumps from high-temperature damage caused during system abnormalities like deadheading, construction usage, and VFD (Variable Frequency Drive) troubleshooting errors, all while reducing water waste and increasing overall system efficiency.

“Our thermal relief valves, the ECONO/HAT-RA valves, are often used on pump systems with an NSF/ANSI 61 requirement. Because of this, our customers must obtain approval to use our valves with every system sold.

The benefit of this certification is that the approval will no longer be needed on the customers’ end. This streamlines sales and encourages system engineers to use our products without fear of added internal cost,” explains OEM Sales Manager Tim McCollum, who was instrumental in the valves’ certification.

In addition to the stainless steel ECONO/HAT line, the valves that are now certified include the stainless-steel valves in the HAT and IC lines:

“Listening to our customers is essential to our business, and obtaining this NSF/ANSI 61 certification to streamline the valve ordering process will save time and money for our customers, something ThermOmegaTech® strives to do daily,” McCollum says.

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ThermOmegaTech to Attend Process Expo 2023 in Chicago to Feature In-Demand Maintenance and Safety Solutions

THERMOMEGATECH ATTENDING PROCESS EXPO 2023 IN CHICAGO AT MCCORMICK PLACE TO SHOWCASE SAFETY AND MAINTENANCE PRODUCTS ON OCTOBER 23-25

(Warminster, PA, USA) ThermOmegaTech is excited to attend the Process Expo 2023 at McCormick Place in Chicago, IL, on October 23-25. Industrial Sales Manager Andy Reichlin, OEM Sales Manager Tim McCollum, and Industrial Account Manager Kristine Wonderly will feature their thermostatic solutions for maintenance and safety with the STVM® Washdown Station, Therm-O-Mix® Tepid Water Delivery Station, ESS Tepid Water Heater, and Thermal Relief Valves for pumps at Booth #4350.

THERMOMEGATECH PRODUCTSWashdown & Tepid Water Group at the Process Expo

ThermOmegaTech’s highest priority is safety! They have developed tepid water solutions for emergency showers and eyewash stations to meet OSHA and ANSI requirements, and also prevent water lines from freezing or overheating to protect personnel and ensure a safe working environment.

Factory-packaged with ThermOmegaTech’s Therm-O-Mix®, the ESS combines cold and tank-heated hot water to deliver a constant 85°F tepid water outlet temperature at the point of use. The unit is completely mechanical and requires no outside electricity to function, making it particularly ideal for explosion-proof industrial environments. See how the Therm-O-Mix® station works here.

Federal regulations require that any facility where workers may be exposed to hazardous or corrosive materials must have immediate access to a tepid water emergency drench system to protect the eyes and body in the event of accidental exposure. The Therm-O-Mix® station consistently supplies tepid water on demand to these fixtures to meet OSHA and ANSI Z358.1 safety requirements. Read more about ThermOmegaTech’s Therm-O-Mix® station here.

ThermOmegaTech supplies an innovative solution to the challenge of difficult-to-maintain steam and water mixing stations used to provide a high-temperature washdown for sanitization procedures at processing plants. See how the STVM Washdown station works here.

ThermOmegaTech is also very interested in speaking with end users of our valves, STVM Washdown Station, and the Therm-O-Mix for case studies and testimonials.
Stop by Booth #4350 at the Process Expo for more information.

We look forward to seeing you at the Process Expo!

The Importance of Industrial Washdown Stations in Food Processing Facilities

Industrial washdown stations are often used in manufacturing, chemical or petrochemical, and food processing facilities as part of cleaning and sanitation procedures where maintaining hygiene is crucial. A bucket of water with a mop and a cleaning agent does not effectively sanitize a plant the way food processing cleaning equipment can.

Cleaning and Sanitation Procedures in the Food Industry

Food assembly workers on Plant Line

Using industrial washdown systems for food processing is important because they help to keep the facility clean and sanitary. They also help to prevent the spread of bacteria and viruses.

Authoritative agencies like the FDA have defined sanitation requirements that each facility must adhere to such as identifying hazards that could impact a production facility.

Food production and detergent residue, liquid, and airborne contamination, transient soil, and microorganisms often are present in food production facilities, which is why washdown stations are recommended in these corporations.

While the hazards present on a production line vary from facility to facility and depend primarily on the specific products produced, they all must be effectively and routinely removed to preserve sanitation and product quality.

Using food processing cleaning equipment can help to reduce costs, too. Regular maintenance and repair of equipment can help to reduce downtime, saving your facility time and money. Regular cleaning and disinfecting of surface areas can also help to reduce labor costs while following a daily process.

Food Processing Cleaning Equipment Limits Downtime

Industrial washdown stations can be used in both commercial and industrial production facilities and are described as stationary equipment that produces a high-pressure and high-temperature stream of water to remove debris while cleaning. However, when used in production facilities such as food processing for meat and dairy, this cleaning equipment offers a fast and efficient cleanup while maintaining sanitation standards.

Food processing cleaning equipment for food processing typically utilizes stations that produce water temperatures at 150°F (65.5°C) or above to quickly cleanse and sanitize surfaces like processing equipment, walls, floors, and other surfaces.

To properly follow cleaning and sanitation procedures for food processing, a washdown system frequently includes a mixing valve that combines hot and cold water along with an industrial-use cleaning agent, if needed.

Using Food Processing Cleaning Equipment Sanitize

Having efficient cleaning equipment in a food processing facility can provide several benefits. By keeping the facility clean, the risk of food contamination is minimized. Food allergies and foodborne illnesses caused by bacteria and viruses can be avoided.

ThermOmegaTech created several washdown systems that offer high-temperature sanitation and maintenance equipment necessary for industrial and food facilities, including steam and water washdown stations with hot water mixing unit hose stations.

To be even more effective, ThermOmegaTech created a specific mixing valve that combines steam and cold water to create a steam water mixing station that lowers the decibel sound in facilities while producing a flow of user-defined stream of water to efficiently sanitize, clean, and kill bacteria.

Choosing The Right Equipment for Food Plant Sanitation

Choosing the right washdown station for your facility can be a challenge. There are a few key factors that should be considered when choosing the equipment for food plant sanitation. Staff should receive proper training on the washdown station when using such as donning the correct clothing and protective gear as well as regularly inspecting and cleaning your equipment.

The ThermOmegaTech® STVM® Washdown Station is used in many processing facilities where a high-temperature washdown is required. The STVM® industrial washdown station combines steam and cold water at a user-set temperature using its proprietary mixing valve.

STVM Steam and Water Washdown Station for Talking With TOTS for Industrial Sanitation

STVM® Steam & Water Washdown Station

The unique Venturi valve throttles open and closed, using a scouring action that minimizes the buildup of minerals, offering a quieter wash without the ‘water hammer effect.’ Plus, the in-line cartridge is easy to replace or clean with no special tools required and takes just a few minutes.

Ultimately, food processing cleaning equipment is an essential component of food-processing plants. They offer a dependable, safe, and easy-to-implement way of keeping these facilities clean and sanitized.

By following the correct processes and safety protocols, companies can ensure that their food-processing facilities are well-maintained and properly sanitized as well as sustain production line schedules.

Questions? We can help! Find more info here or contact us.

ThermOmegaTech Launches New Safety and Maintenance Content at Safety Show ’23 in San Antonio

ThermOmegaTech’s highest priority is safety, where we have developed tepid water solutions for emergency showers and eyewash stations to meet OSHA and ANSI requirements, and also prevent water lines from freezing or overheating to protect personnel and ensure a safe working environment.

ThermOmegaTech recently attended the ASSP Safety Show in San Antonio, Texas, and launched new safety and maintenance content. Andy Reichlin, Industrial Sales Manager, and Tim McCollum, OEM, showcased their thermostatic solutions for maintenance and safety with the STVM® Washdown StationTherm-O-Mix® Tepid Water Delivery StationESS Tepid Water Heater, and Thermal Relief Valves for pumps.

ThermOmegaTech Products

Federal regulations require that any facility where workers may be exposed to hazardous or corrosive materials must have immediate access to a tepid water emergency drench system to protect the eyes and body in the event of accidental exposure.

The Therm-O-Mix® station consistently supplies tepid water on demand to these fixtures to meet OSHA and ANSI Z358.1 safety requirements.

Tepid Water Delivery System, Therm-O-Mix® station

Therm-O-Mix®

Read more about ThermOmegaTech’s Therm-O-Mix® station here.

Factory-packaged with ThermOmegaTech’s Therm-O-Mix®, the ESS combines cold and tank-heated hot water to deliver a constant 85°F tepid water outlet temperature at the point of use. The unit is completely mechanical and requires no outside electricity to function, making it particularly ideal for explosion-proof industrial environments.

See how the Therm-O-Mix® station works here.

ThermOmegaTech recently launched a new STVM video in their video series, Talking with TOTs, that speaks to the effectiveness of the STVM® Washdown Station. In the video, Senior Product Specialist Glenn Quinty takes the viewer through the ease of maintenance and the safety of the washdown station. “It’s so important to maintain a clean environment in food processing, chemical, petrochemical, and pharmaceutical facilities,” Quinty says.

STVM Steam and Water Washdown Station for Talking With TOTS for Industrial Sanitation

STVM® Steam & Water Washdown Station

See the STVM® Washdown Station Talking With TOTs video here.

ThermOmegaTech supplies an innovative solution to the challenge of difficult-to-maintain steam and water mixing stations used to provide a high-temperature washdown for sanitization procedures at processing plants.

See how the STVM Washdown station works here.

Food Industry Executive tells us more here!

ThermOmegaTech Launches New Talking with TOTs Video Featuring STVM® Washdown Station

Video Focuses on High-Temperature Washdown Equipment For Industrial Sanitation

ThermOmegaTech is excited to introduce their newest Talking With TOTs video, featuring Senior Product Specialist Glenn Quinty on ThermOmegaTech’s STVM® Washdown Station.

“We know how critical it is to maintain a clean environment in food processing, dairy, beverage, chemical, petrochemical, and pharmaceutical facilities,” Quinty says. “High-temperature washdown equipment is used to quickly and efficiently clean and sanitize equipment in place to keep production running on time.”

Washdown stations are recommended in food production facilities where transient soil, food production residue, and microorganisms can be present. Not every facility encounters these hazards depending on the specific product it produces, but removing debris, cleaning, and sanitizing is essential to preserving sanitation and product quality.

Steam Water Mixing Valve for Sanitization

Simply put: sanitizing kills bacteria.

Industrial Sanitation comprises several sequences created to protect workers’ health and safety in industrial environments and designed to protect the environment from pollution and industrial waste.

With high temperature washdown equipment, industrial sanitation is achievable. In the Talking with TOTS video, Quinty takes viewers through the washdown process, demonstrating how ThermOmegaTech’s proprietary Silent Venturi Mixing Valve (STVM®) combines steam and water to a user-defined temperature.

STVM Steam and Water Washdown Station for Talking With TOTS for Industrial Sanitation

STVM® Steam & Water Washdown Station

“The steam and water mixing valve’s design is self-scouring, which prevents mineral buildup in tight spaces and reduces maintenance frequency. Maintaining competitor steam and water mixing stations can be time-consuming due to complex disassembly, special tooling requirements, and non-reusable components,” Quinty says.

The compact, reliable, and entirely mechanically operated STVM® Washdown Station is beneficial to any industrial processing plant’s sanitation procedures.

It is more durable and at least 8-15 decibels quieter when compared to competitor units, as found in recent testing.

How to Choose the Right High Temperature Washdown Equipment for Your Facility

Choosing the right washdown equipment can be a challenge, taking into account your facility’s needs and government regulations.

To minimize maintenance downtime and get production lines moving again, the STVM® station is in-line serviceable. The operator simply switches out the STVM® mixing valve cartridge with a spare using a standard wrench, and the unit is operational again in minutes. In contrast, competitor stations must be removed from the wall and completely disassembled to repair, which takes hours and results in more extended downtime.

Operator’s safety is another crucial element that positions the STVM® Station above the competition. Employees should wear the correct PPE (personal protective equipment — including gloves, masks, smocks, etc.) when operating any washdown equipment and have the proper training on the unit. In addition to these safety guidelines, our station has two safety features to help keep your employees safe.

“The mixing valve is designed to reduce flow if the output temperature exceeds the factory set-point and will completely stop flow 15°F above that,” Quinty notes in the video. “The station also has interlocking steam and water shut-off ball valves, so both inlets shut off at the same time to prevent accidental steam-only operation.”

Using food processing cleaning equipment can help to reduce costs, too. Regular maintenance and repair of equipment can help to minimize downtime, saving your facility time and money. Regular cleaning and disinfecting of surface areas can also help to reduce labor costs while following a daily process.

Watch the full Talking With TOTs video here.

If you have questions about the STVM® Washdown Station or want information on pricing and lead times, please don’t hesitate to contact us or one of our authorized distributors.

How an East Coast Rail Company Prevents Their Locomotives From Freezing

The GURU® Plug – The #1 Freeze Protection Valve

Freeze protection is essential for locomotives during winter months to prevent catastrophic damage to equipment. A diesel locomotive’s cooling system is at risk of freezing when the locomotive is turned off. If the cooling water freezes, it can cause the piping and tanks to crack, resulting in extensive damage, lengthy repairs, and interrupted schedules.

GURU PLUGOperators could keep their locomotives running at all hours to prevent a freeze-up, but that can contribute to air pollution and fuel waste. Another more cost-effective and efficient way is to install ThermOmegaTech’s GURU® Plug.

The Opportunity

The GURU® DL2.1  thermostatic drain valve is installed at the lowest point within the cooling system and automatically responds to engine coolant temperature.

The Plug will snap open and drain the system if the water temperature reaches the Plug’s set point, typically 35°F. This provides almost a full one-inch bore to rapidly drain a typical locomotive’s coolant system before freeze damage can occur. The Plug can be reset when the operator is ready to refill the locomotive and return it to service.

SMS Locomotive using GURU Plug

SMS Rail Lines, a one-stop provider of rail distribution services to businesses along the Washington, D.C. to Boston corridor, is based in Bridgeport, New Jersey, and has been using ThermOmegaTech’s GURU® Plugs for over a decade on their locomotive cooling systems and compressors.

SMS Rail Lines operates over 6 miles of track throughout Pureland Industrial Park in Bridgeport, New Jersey, providing service daily, including on-demand rail switching and daily interchange with Class I railways CSX Transportation and Norfolk Southern Corporation.

SMS Rail Lines also offers rail-to-truck and truck-to-rail transloading, warehousing, distribution services, and rail car storage at this location, with 12 locomotives in service at any given time. Additionally, the company restores, maintains, and operates historic Baldwin diesel locomotives.

Utilizing the GURU® Plug

“We normally have 12 to 14 locomotives in service at any given time,” General Manager Brian Murray explains. “Some of our locomotives have only a single GURU if they are plumbed in a way where everything can drain to a central location. We have a couple with a second GURU to handle additional low points in the cooling system. Our GE locomotives have 4 GURUs. They have 2 GURUs to handle low-point general draining and 2 on the low-pressure heads of the water-cooled air compressor.”

SMS operators have previously used other freeze protection devices on their locomotives. “We initially used ‘that other name brand.’ It would occasionally open while the engine was hot and running,” said GM Murray. Because of this, he looked for another solution and was introduced to ThermOmegaTech’s GURU® Plugs over ten years ago by then-product manager Dana Logue.

The GURU® Plug Rebuild Program

The GURU® Plug satisfied their needs and came with an additional perk – the GURU® Rebuild Program. ThermOmegaTech® offers a rebuild program for the self-actuating GURU® Plug, which protect thousands of locomotives from freeze damage annually. The program allows customers to return their old GURU® Plugs to be cleaned, refurbished, retested, and returned, so customers get back an almost brand new valve.

“We are very happy with ThermOmegaTech® and think the GURU® Plug is terrific. We have never had a GURU fail to open when necessary. As the end user, we should probably do a better job at keeping track of which GURU plug is in which locomotive and how old they are,” stated GM Murray.

Brian with Guru Plug

Luckily for SMS Rail Lines, there’s an easy way to track that!

Each GURU® Plug has a yearly-rotated color cap which is also laser marked with its month and year of manufacture. ThermOmegaTech® recommends changing the GURU® Plugs every 18-24 months, as the GURU® Plug’s actuator loses a small amount of stroke as it ages beyond one year. This stroke loss causes the release temperature and the manual reset temperature to creep upward. While this is a “safe” tendency for freeze protection, the upward creep can eventually cause nuisance dumping.

The colored caps rotate through 5 colors over 5 years and visually indicate the year it was built. Maintenance personnel can compare the cap’s color against our chart to determine when it needs to be sent back for rebuild. SMS has taken advantage of this perk and utilizes the rebuild program yearly.

“We send in about 4 or 5 valves per year for rebuilding to have them on hand. Our cost savings are significant as we have a lot of older GURUs around, so it makes sense to rebuild them,” says GM Murray.

And when they come back, rebuilt, and refurbished, GM Murray says they are good as new, and they’ve never had any issues.

The Result of the GURU® Plug

GURU Plug on locomotive

“In my experience, all the folks at ThermOmegaTech® are genuinely interested in providing to the railroad industry effective, reliable solutions. The staff is always accessible and willing to work cooperatively with the customer to examine the need and suggest the appropriate product,” says James Pfeiffer – Superintendent of Operating Practices.

“Customer feedback is welcomed, technical questions are quickly answered, and the engineering department is seemingly always working on something new and improved. And they do all this while maintaining first-class customer service.”

If you are interested in hearing more about Locomotive Freeze Protection and how the GURU® Plugs can help save you time, energy, and money, we’d love to help. Contact us today.

Read the full GURU® Plug case study here.

Hear how it works with our Talking With TOTS video!

Full Steam Ahead: Sanitizing with Steam and Water Mixing Stations Whitepaper

Washdown stations ensure cleanliness in food processing, dairy, breweries, wineries, chemical, petrochemical, pharmaceutical, and other industrial facilities where a high-temperature washdown is required.

Traditional cleaning methods include soap, hot water, and sometimes chemical disinfectants. These procedures may require breaking down equipment to ensure all components are efficiently cleaned and sanitized. If chemicals are used to sanitize a processing plant, especially in food and beverage, labor costs, the possibility of safety hazards, and the overall sanitization time increase.

Utilizing a Steam and Water Mixing Valve to Sanitize Processing Plants

Sanitizing your facility or plant using a steam and water mixing valve is one of the most efficient ways. Using steam to heat the water is more beneficial than chemical cleansing because it avoids chemical agents and can reduce labor times and water consumption.

Steam and water mixing valve stations provide instantaneous high-temperature steam-heated water with pressure behind it, which can kill bacteria, sterilize, and break down greases and other residues in processing plants. The World Health Organization states that bacteria are rapidly killed at temperatures between 149°F and 185°F degrees.

There’s also less downtime for dismantling and reassembly when utilizing steam-heated water to sanitize manufacturing equipment. Steam is sterile as well as being an excellent carrier of heat. Harmful chemicals are also used less or not at all, allowing for more uptime and a safer environment for personnel; while they are doing their jobs.

Not just anyone can utilize high-temperature steam and water mixing washdown stations. Plant personnel must be trained on proper use to ensure safety because the goal is to sanitize, and the goal of the plant is safety.

STVM® Steam & Water Washdown Station

STVM Steam and Water Mixing Valve Washdown Station

ThermOmegaTech’s STVM® Steam & Water Washdown Station has been designed to put the safety of maintenance operators first. Every STVM® Washdown Station is built-to-last and has two built-in safety features – interlocking ball valves to prevent steam-only operation and an automatic shut-off when output is 15°F over the unit’s temperature set-point (either 150°F or 185°F) or when cold water flow is interrupted.

This Washdown Station also incorporates unique Venturi mixing technology to deliver water at the required temperature quickly, quietly, and on demand.

The ‘ST’ in STVM stands for ‘Silent Type,’ meaning it is quieter than other washdown mixing stations. The Venturi effect mixes water in smoother than other steam-to-water mixing stations on the market, which can cause cavitation downstream of the mixing valve.

The steam-supplied station is a self-contained mechanical control unit, so it doesn’t require external hookups for electrical, instrumentation controls, or compressed air.

Find out how the STVM washdown station can efficiently clean your facility. Read more and download the Full Steam Ahead Whitepaper.

2022: ThermOmegaTech’s Year in Review

2022 was a fantastic year, thanks to our customers! ThermOmegaTech® has been able to meet its goals despite facing industry-wide supply chain issues. Let’s celebrate ThermOmegaTech’s Year in Review!

2022 HIGHLIGHTS

Here are some of the significant accomplishments we are celebrating from our Industrial Market:

  • Andy Reichlin joined our team in March as our Industrial National Sales Manager. Andy has held roles in communications, marketing, and sales, managing national distribution networks for various industrial products, including bearings and pumps, over the last 20 years. His expertise has helped us to grow our distribution network and support our authorized distributors.
  • We hosted our first inaugural Distributor Advisory Council, which included representation from six authorized distributors. This was incredibly beneficial as they were able to tour our facility, and we could share ideas and resources for the upcoming year.
  • We also added two new U.S. distributors, Industrial and Construction Enterprises and Schimberg Co., and two new International distributors, Glotex and Tubes International.

NEW LITERATURE & VIDEOS

  • We launched an eBook with Food Processing Magazine in November ’22 on how sanitizing food processing facilities with steam-heated water provides a simple and efficient way to maintain a sterile work environment. Download it here.
  • We created a whitepaper on the Steps to Developing an Effective Sanitization Procedure in plants and facilities, which you can download here.
  • We also released this application sheet on Thermostatic Control Valves for Cooling Balancing Applications.
  • We were excited to release this video on HCX and HCS Washdown Stations for Breweries, Wineries & Other Facilities Without Steam. To ensure a high-powered wash that guarantees cleanliness in production facilities, ThermOmegaTech® offers the most economical, safe, and efficient washdown systems and equipment.

TRADESHOWS WE ATTENDED

ASSP Expo 2022: Industrial Safety Trade Show

We had a great time networking and meeting associates at the 2022 ASSP Expo.

Here are some of the great accomplishments that we’d like to share with you from our Rail Division:

  • Increased sales steadily as we moved out of the pandemic and remained the leader in locomotive freeze protection for all the Class I’s in North America.
  • Significant growth in the passenger car freeze protection market thanks to a big focus on the GURU PC® with its electric heater assembly to ensure prospects are aware of the need for freeze protection and options available for passenger cars.
  • Dana Logue, Engineering Project Manager, and Glenn Quinty, Senior Engineering Product Specialist, participated in RT&S Railway Age Virtual Conference: Winter Preparedness. Watch it on demand here!

Here are some of the outstanding accomplishments that we’d like to share with you from our Commercial Plumbing Division, CircuitSolver®:

  • We launched the new CircuitSolver Union Cold Water balancing valve (CSU-CW). This valve automatically and continuously balances a cold water recirculation system to discourage Legionella bacteria colonization and reduce stagnation.
  • Project Manager Eric McTee of ME Engineers details his experience specifying CircuitSolver® over the last few years in this testimonial.
  • We released two new videos, a How it Works video on CircuitSolver® and one on the new Cold Water CircuitSolver® valve.
  • Read more about CircuitSolver’s Year in Review on the CircuitSolver® website.

Here are some of the great accomplishments that we’d like to share with you from our Aerospace and Defense Division:

  • We hired Josh White as our A&D Business Development Manager and are excited about his work in the Aerospace and Defense Division. Josh is a former Air Force One pilot with over 20 years of operational military aviation experience. His expertise and skills in the aerospace industry will help us to develop new processes and streamline our strategies to serve our customers better.
  • We have brought on a new A&D rep J.D. Technologies Global, who works with high-quality, complementary manufacturers of products and services that serve the aerospace, military & defense, medical, and industrial markets. We are very excited about this partnership and proud of the work we’ve done with them in 2022, and looking forward to 2023.
  • Read more about our A&D Division’s Year in Review on the Aerospace & Defense website.

Looking Forward

Our Electronics Affiliate, TJM Electronics, has merged with ThermOmegaTech® and will now operate under the ThermOmegaTech® brand as our Electronics Division! Read about this breaking news here!

Thank you for being a part of our journey, and have a happy New Year! We look forward to working with you in 2023!

TJM Electronics to Merge with ThermOmegaTech

TJM Electronics Merger Announcement

Electronics manufacturer to merge with affiliate company.

(Warminster, Pennsylvania) TJM Electronics is pleased to announce that it will merge with its affiliate company, ThermOmegaTech. Effective January 1, 2023, TJM will operate under the ThermOmegaTech brand as their electronics division.

TJM Electronics has been leading the way in electronics contract manufacturing since 1989. TJM became one of the first automated SMT companies certified to MIL-STD-2000 on the East coast. Since then, TJM has provided high-quality PCB assemblies utilizing cutting-edge technology to the aerospace, defense, medical, industrial, LED lighting, and non-commodity consumer electronics markets.

In 2019, TJM was purchased by Logue Family Holdings, the parent company of ThermOmegaTech, a leading thermostatic valve, and actuator design and manufacturing corporation. For almost 40 years, ThermOmegaTech has been creating temperature control solutions for a wide range of applications and currently services the railroad, commercial plumbing, aerospace, defense, and an array of industrial markets.

Last summer, TJM moved from its Bristol location to its current facility in Warminster, PA, located in the same building as ThermOmegaTech’s manufacturing plant and office space.

“This merger is a huge strategic advantage for TJM as it will help streamline processes and improve communication channels throughout the organization,” said Jim Logue, Jr., President, CEO of ThermOmegaTech and TJM Electronics. “Combining ThermOmegaTech’s mechanical design and manufacturing capabilities with TJM’s electrical manufacturing abilities will open the door to new opportunities and help to continue growth in our current markets.”

This partnership is also expected to result in greater efficiencies and eliminate redundancies in their systems, such as combining the AS9100D certification for both companies into one.

As with all important business decisions, ThermOmegaTech will work closely with its customers and employees to make the integration process as smooth as possible. Beyond the name change, customers should not see any major changes in the products and services they receive from both companies.

 

About ThermOmegaTech, Inc:

For almost 40 years, ThermOmegaTech has been a leader in designing and manufacturing self-actuated thermostatic technology valves and actuators. Founded in 1983, ThermOmegaTech is a privately held small business with 40,000 square feet of manufacturing and office facility located near Philadelphia, Pennsylvania.

The company provides innovative solutions for various applications, including freeze & scald protection, mixing & diverting, steam tracing control, thermal bypass, tepid water delivery, washdown, balancing, drain tempering, and many others applications where temperature control is critical. Key industries it serves include railroad, commercial plumbing, aerospace & defense, and industrial.

ThermOmegaTech specializes in manufacturing prototype/small volume and highly engineered custom products utilizing phase-change thermostatic actuator technology to satisfy individual project needs.

ThermOmegaTech’s R&D, manufacturing, assembly, testing, inspection, sales, and customer service departments are all located in one facility for maximum efficiency and effective communication. Its QMS is certified to AS9100D standards demonstrating the focus on quality, and its products are distributed and used worldwide.

ThermOmegaTech and Grundfos Announce Partnership

This month, ThermOmegaTech and Grundfos announced a partnership, bringing together two industry leaders to simplify and enhance domestic plumbing systems and installations for contractors throughout the United States.

Beginning in late Q1, the partnership will offer a new packaged solution featuring ThermOmegaTech’s CircuitSolver® product line with the appropriate pump from the Grundfos MAGNA Series.

“We are excited about growing our relationship with a well-respected worldwide company like Grundfos,” said Tom Ruggierio, national business development manager at ThermOmegaTech. “Having two companies with innovative, synergistic products working together will bring optimized solutions for domestic hot water systems that will serve the plumbing community well.”

The partnership supports the companies’ shared goals of enhancing the accessibility and conservation of water, our most precious resource, by providing solutions that exceed energy and efficiency standards. “Working together allows us to save time for contractors who no longer need to source the appropriate pump style and size,” said Ruggierio. “The CircuitSolver® solution will now come with an expert-recommended pump, allowing contractors to focus their efforts on what they do best — the installation.”

“We continue to be impressed by the innovation of our ThermOmegaTech partner. Joining forces is a win-win opportunity for both companies as well as our manufacturer representatives, contractors, and the homeowners,” said Barry Nauss, Grundfos vice president of HVAC OEM. “When used together, our products greatly minimize water consumption and increase energy efficiency by optimizing the recirculating flow rate. This ensures the precise amount of water and power are utilized as water rotates through the system versus flowing down the drain. We’re proud to offer our new, sustainability-focused packaged solutions to the market.”

Grundfos and ThermOmegaTech will also offer expert training sessions together in 2022 with the goal of increasing awareness of the benefits their product portfolios bring to a domestic hot water system.