Proper management of temperature distribution is essential to ensure consistent product quality. However, temperature imbalances and variations are a challenge for many companies, and can lead to quality issues and reduced production efficiency.
In this article, we will explain what temperature distribution is, how it affects companies, and how to efficiently measure it and improve it.
The purpose and importance of temperature distribution
Temperature distribution refers to the temperature deviation or unevenness in a specific space within a product, material, or manufacturing equipment. This temperature deviation can have a significant impact on the stability of quality and product performance.
For example, in food manufacturing, it is important to ensure that products are properly heated and cooled all the way to the core, and in pharmaceutical manufacturing, it is important that storage temperatures are maintained constant.
Accurately understanding and managing temperature distribution is essential for maintaining consistent product quality and reducing the occurrence of defective products.
Temperature Mapping Concept and Purpose
Temperature mapping, which is closely related to temperature distribution, is a technique for measuring the temperature at multiple locations within a specific space or device simultaneously for a certain period of time, and then recording and analyzing the distribution in detail.
This method is intended to confirm temperature uniformity, ensure quality, and comply with regulations for pharmaceuticals, food, etc. Analyzing the data and using it to develop improvement measures also contributes to optimizing the manufacturing process and improving quality.
Temperature unevenness during heating and cooling processes
Temperature unevenness is likely to occur during the heating and cooling process, especially inside ovens and dryers, where uneven heating occurs due to the distance from the heat source, air convection, and product placement.
Uneven temperature during drying and storage process
In the dryer, uneven drying can occur depending on the shape and placement of the product, as well as the type of dryer, resulting in uneven moisture content. In addition, in large warehouses and storage facilities, temperature differences are likely to occur due to external heat, air conditioning, and the way products are stacked, so particular care must be taken near walls and windows.
Drying and storing products in an environment with uneven temperatures can lead to product deterioration, spoilage, and mold growth, and in the case of food and pharmaceutical products, it can also pose safety issues.
Temperature distribution in facilities and equipment
The equipment and devices themselves on the production line can also have temperature distribution problems. In thermostatic chambers and incubators, slight temperature differences can occur depending on the placement of heaters and fans and how often they are turned on and off, which can affect precision testing and cultivation.
Furthermore, hot and cold spots can occur in pipes and tanks due to heat transfer, stagnation of contents, and uneven flow rates, which can lead to reduced reaction efficiency, deterioration of contents, and damage to equipment.
Occurrence of product defects
Uneven temperature distribution has a direct negative impact on product quality.
For example, uneven soldering temperatures in the manufacturing process of electronic components can cause poor joints and shorten the product’s lifetime. In food manufacturing, insufficient heating can lead to the growth of microorganisms, while overheating can cause a deterioration in flavor. Furthermore, in the manufacturing and storage of pharmaceuticals, temperature deviations can lead to the deterioration of ingredients and a reduction in their effectiveness, and in the worst-case scenario, can have a serious impact on people’s health.
To improve customer satisfaction and build trust as a company, it is essential to prevent product defects caused by temperature distribution.
Decreased quality stability
Products manufactured in an environment with uneven temperature distribution are more likely to have individual differences.
For example, if there is temperature unevenness during the cooling process of a resin molded product, the shrinkage rate of the product will vary, and dimensional accuracy may become unstable.
This can lead to processing defects and assembly problems in later processes, reducing the overall stability of quality. If you cannot consistently supply products of consistent quality, you may lose the trust of your customers.
Deterioration in yield
For example, if only some products burn or are not dried sufficiently in a particular heating furnace, those products will have to be discarded, resulting in lower production efficiency and wasted raw material and processing costs.
A decline in yield makes it difficult to achieve production plans, which directly puts pressure on a company’s profitability.
Thermocouples and resistance thermometers
Thermocouples and resistance thermometers are highly accurate temperature sensors suitable for continuously measuring the temperature of a specific point.
Thermocouples use the thermoelectric power at the junction of two different metal wires to measure high temperatures, while resistance thermometers use the change in electrical resistance of metals to make stable measurements.
Thermography
Thermography is a device that detects infrared rays emitted by an object and displays the temperature as an image, and has the advantage of being able to visualize temperature distribution over a wide area in real time without contact.
This helps to detect abnormal heat generation areas early and grasp the overall picture of uneven heating and cooling, and is also suitable for measuring the temperature of operating equipment and products.
Temperature Data Logger
A temperature data logger is a device that connects to a temperature sensor and automatically records temperature data. It can continuously record temperature changes over a long period of time, which is useful for comparing with past data and analyzing trends.
Other features include unmanned data collection, which reduces labor costs and saves labor, and data analysis and graph display via PC connection.
Temperature distribution control is essential for stable quality and improved competitiveness. Temperature variations that can occur during heating, cooling, drying, storage processes, and inside equipment can lead to product defects and reduced yields.
To tackle these issues and making temperatures visible as a first step, we recommend using our easy-to-use temperature indicating material.
As a first step to solving these issues and making temperatures visible, we recommend using our easy-to-use temperature indicating material (Temperature Label).