High-Capacity Double-Deck Natural Gas Drying Oven for Industrial Pulp Molding

High-Capacity Double-Deck Natural Gas Drying Oven for Industrial Pulp Molding

Composition of Production Line

This space‑optimized drying system includes:

• Motorized Infeed Conveyor — variable speed, compact design, with manual or automatic product loading station

• Double‑Layer Insulated Drying Tunnel — two vertically stacked drying chambers (lower deck + upper deck), high‑density rock wool insulation (100–120 mm)

• Integrated Natural Gas Burner Unit — compact direct‑fired burner, stainless steel heat exchanger, modulating control valve

• High‑Efficiency Air Circulation Fans — two fans (one per deck) with variable speed control, adjustable air distribution louvers

• Exhaust System with Adjustable Dampers — for humidity control and moisture removal

• Compact PLC Control Panel — wall‑mount or machine‑mount design, 7″ touchscreen HMI, basic recipe storage (up to 30 recipes)

• Temperature Monitoring System — PT100 sensors in each deck with digital display

• Outfeed Conveyor — with product collection tray or manual unloading station

• Gas Safety Interlock System — flame detector, gas leak sensor, manual shut‑off valve, emergency stop button

The system is designed for a compact footprint, suitable for facilities with limited floor space. The total length can be as short as 6 meters for small‑scale production.

Product Description

This Compact Double‑Layer Natural Gas Dryer is specifically designed for small to medium‑sized pulp molding operations, pilot production lines, or facilities with severe space constraints. By stacking two drying chambers vertically, this system achieves double the drying capacity of a single‑deck dryer while occupying the same floor area — typically requiring only 6–15 meters of linear space compared to 12–30 meters for a comparable single‑deck system.

The dryer uses direct gas‑fired heating with forced hot air circulation. Natural gas is burned in a compact, high‑efficiency modulating burner, and the hot air is circulated independently through each deck. The lower deck and upper deck have separate temperature controls and airflow adjustments, allowing flexible operation for different product types or different drying stages. Despite its compact size, the system maintains high drying uniformity and energy efficiency.

The compact design is ideal for manufacturers who are:

• Expanding production but have limited floor space

• Setting up a pilot or R&D drying line

• Producing small‑batch, high‑value pulp molded products

• Operating in multi‑story facilities where horizontal space is limited

• Retrofitting an existing production line with limited space for additional drying capacity

The system is pre‑assembled and tested at the factory, shipped as a modular unit, and can be installed and commissioned in significantly less time than larger systems. All components are designed for easy access and maintenance despite the compact configuration.

Technical Parameters

Application

• Small to medium‑scale pulp molding production — 500–2000 kg/hour capacity range

• Pilot lines and R&D facilities — for new product development and process optimization

• Specialty pulp molded products — small‑batch, high‑value items (cosmetics packaging, premium food containers, electronics inserts)

• Start‑up pulp molding operations — affordable entry‑level drying solution with expansion capability

• Multi‑product facilities — frequent changeover between different product types

• Facilities with limited floor space — multi‑story factories, retrofits, space‑constrained layouts

• Educational and training facilities — teaching pulp molding technology

Customization

This compact dryer offers flexible customization for diverse applications:

• Customizable tunnel length — from 6 meters (minimum) to 15 meters (maximum), allowing capacity scaling without changing machine width

• Customizable drying width — from 400 mm (narrow products) to 1000 mm (standard trays)

• Customizable belt type — stainless steel mesh (standard), PTFE mesh (non‑stick), chain conveyor (heavy products), or wire belt (high airflow)

• Customizable deck clearance — independent adjustment of upper and lower deck heights for different product thicknesses

• Customizable temperature range — standard 50–150°C, high‑temperature option up to 250°C for specialized applications

• Customizable fuel type — natural gas, LPG, or biogas; dual‑fuel capability available

• Customizable control system — basic manual control (dials and switches) or full PLC automation with touchscreen

• Customizable conveyor loading/unloading — manual loading station, semi‑automatic, or full integration with upstream forming machines

• Customizable safety package — additional gas detectors, light curtain, area scanner

• Customizable voltage and frequency — for any global location

• Customizable color and branding — OEM customization available

Feature

• Compact footprint — occupies 40–50% less floor space than a comparable single‑deck dryer, ideal for space‑constrained facilities

• Pre‑assembled and tested — shipped as modular unit, significantly reduced on‑site installation time (typically 3–5 days)

• Independent deck control — upper and lower decks can run different products or different drying temperatures simultaneously

• Energy efficient — up to 85% thermal efficiency with optional heat recovery, lower operating costs compared to electric drying

• Quick product changeover — recipe‑based parameter recall (temperature, speed, airflow) for different product types

• User‑friendly operation — intuitive touchscreen interface with real‑time temperature display and alarm indications

• Low maintenance design — accessible burner assembly, swing‑open doors for belt access, easily removable panels

• Flexible fuel options — compatible with natural gas, LPG, and biogas; field‑convertible

• Built‑in safety systems — flame detection, gas leak sensors, automatic shut‑off valves

• Scalable design — add additional tunnel sections or upgrade to larger width without replacing the entire system

• Data logging capability — USB port for exporting drying parameters (temperature, speed, duration) for quality records

• Affordable entry point — lower capital investment than large‑scale systems, ideal for start‑ups and pilot lines

Support and Services

• Lifetime free technical support — phone, email, and video call assistance

• On‑site installation & commissioning — engineers available globally, typically 3–5 days on‑site

• Operator training — 2–3 days on‑site training included; remote training option available

• 1‑year warranty — on all mechanical and electrical components (extended warranty available)

• Spare parts supply — critical spares stocked for 48‑hour express shipping

• Remote diagnostics — VPN access for troubleshooting (available with PLC control option)

• Free sample testing — send your wet pulp molded products; we provide drying test report

• Process optimization support — our engineers help you develop optimal drying parameters for your specific products

• Upgrade path — existing compact dryers can be upgraded with additional tunnel sections, heat recovery, or advanced controls

Packing and Shipping

• Packed in reinforced export‑grade wooden crates with VCI anti‑rust film and foam padding

• Shipped as modular sections (main tunnel body, conveyor decks, control panel, burner unit) for container loading (20ft or 40ft containers)

• Includes: English manual, CE certificate, electrical schematics, gas connection diagram, calibration certificate, tool kit, spare parts kit

• Shipping terms: FOB / CIF / DDP by sea, air freight, or land transport

• Lead time: 20 days for standard configuration; 30–45 days for customized options

• Minimum order: 1 set

FAQ

Q1: How much floor space does the compact double‑layer dryer require compared to a single‑deck dryer?
A1: The compact double‑layer dryer typically occupies 40–50% less floor space than a single‑deck dryer with comparable capacity. For example, a single‑deck dryer requiring 15–20 meters of linear space can be replaced by a double‑deck unit requiring only 8–12 meters. The exact footprint depends on the selected tunnel length and width.

Q2: Can I start with a shorter tunnel length and add sections later as production grows?
A2: Yes. The modular design allows you to start with a shorter tunnel (e.g., 6 meters) and add additional tunnel sections later to increase drying capacity. This is a cost‑effective way to scale your production without replacing the entire dryer. Please consult our engineering team for the modular expansion design.

Q3: Is this dryer suitable for drying thin‑wall products like disposable plates?
A3: Yes. The adjustable deck clearance (150–400 mm) and variable belt speed allow precise control for thin‑wall products. The forced hot air circulation ensures uniform drying without warping. For very thin products (e.g., 0.5–1 mm thickness), we recommend the PTFE mesh belt option to prevent sticking.

Q4: What is the power consumption of the compact dryer (excluding gas)?
A4: The electrical power consumption is relatively low — typically 5–15 kW depending on the number of fans, conveyor motors, and control system. The majority of the energy input comes from natural gas, which is generally more cost‑effective than electric heating for industrial drying applications.