Resource Efficient Innovations Database (REID)

Hybrid plated-tubular heat exchanger delivers significant energy savings

< Back to search results
Hybrid plated-tubular heat exchanger delivers significant energy savings
The fusion heat exchanger combines the open flow of tubular heat exchangers with the energy efficiency of plated heat exchangers.
In Use – This innovation was first brought to the market during the first quarter of 2012, and first installations are expected to take place during this year.

Resource efficiency (e.g. filling line efficiency)

Product Categories
Drinks, Food

Relevant Materials
Not Applicable

Relevant Packaging Formats
Not Applicable

Supply Chain Phase


A new plate heat exchanger has been brought to the market which delivers the open flow advantages of tubular heat exchangers while maintaining the energy efficiency of plated heat exchangers.

The new exchanger features a unique design with a truly open flow and no contact points. It combines the energy efficiency, accessibility and modularity of plate technology with the viscous and particulate-handling capabilities of tubular technology. Thus, the technology is particularly appropriate for viscous and particulate products such as juices, prepared foods, soups and sauces, which have traditionally been processed in tubular heat exchangers.

The new design features a fully accessible 4 to 6 mm open channel on the product side. The open-channel design is made possible by bonded plate cassettes on the media side. The cassettes are bonded using a patented technology, which bonds two stainless plates together into one piece with no joints. This allows the use of thin plates providing optimum heat transfer, and thus maintains a high resistance against product pressure. The unique channel geometry ensures gentle product treatment. Plates can be easily added and removed, providing the flexibility to react to changes in production volume.

Manufactured by Alfa Laval and branded as FusionLine, the equipment can easily be integrated into existing installations and can generate significant operational energy savings. The capital cost is greater than for a traditional plated heat exchanger but in the region of 20-25% lower than that of a traditional tubular heat exchanger.

The content in this entry has been obtained from publicly available information sources only (e.g. press releases, website and trade press articles) and is subject to completion of a validation process with the technology supplier.

Potential Benefits

This solution can help keep production costs down and end-product quality up. Alfa Laval claims potential operational energy savings in the region of 30-35% compared to conventional tubular heat exchangers. This equates to cost savings and a reduced manufacturing carbon impact.
The footprint of the FusionLine is also 30 to 40% smaller than a conventional tubular heat exchanger.

Intellectual Property

The technology is based on cassettes that are bonded using Alfa Laval’s patented AlfaFusion technology.

Consultant View

Readers interested in energy efficiency related innovations in the food and drink manufacturing sector should try searching the REID database for other relevant entries. Useful search term combinations could include “food and drink” and “energy efficiency” and “processing”.

Contacts and Further Information

Achim Heiming, Contherm Product Manager Europe and Competence Centre Manager Thermal
Tel direct: +49 231 1890034
Mobile: +49 171 6423081

Copyright 2013 WRAP | Terms | Privacy Policy | Disclaimer | Cookies Policy Contact Us |