METWAVE Essentia: The Reliable Microwave Solution

Metwave Essentia Industrial Microwave Oven

One of the most important features of the METWAVE Industrial Microwave Oven family is its modular structure. The microwave cavities that make up the modules of METWAVE are formed by combining small microwave generators operating at 2.45 GHz in industrial type. Instead of generating and distributing microwave energy from a large and single generator, the energy generated from many small generators is positioned in the cavity to create a homogeneous energy field. In this way, instead of a single generator that is difficult and costly to import, it reaches a structure that is easy to access, can be replaced quickly and allows the oven to continue production even if a few of them break down. The METWAVE Essentia product has also emerged after the first prototype in the development of the METWAVE Industrial Microwave Oven family.

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Metwave Essentia Industrial Microwave Oven

One of the most important features of the METWAVE Industrial Microwave Oven family is its modular structure. The microwave cavities that make up METWAVE’s modules are composed of small industrial microwave generators operating at 2.45 GHz. Instead of generating and distributing microwave energy from one large generator, the energy generated from many small generators is positioned in the cavity to create a homogeneous energy field. In this way, instead of a single generator, which is difficult and costly to import, it is easy to access, quick to replace and allows the oven to continue production even if several of them break down. The METWAVE Essentia product is the first prototype in the development of the METWAVE Industrial Microwave Oven family.

This product, each module of which has 16 kW microwave power, is designed to have a total microwave power of 48 kW by combining 3 modules side by side. In the conveyor belt system, the products are loaded from one side, pass under the silencers that prevent microwave leakage and exit the machine outlet by passing under each module respectively. This structure, which can be seen in the photo below, allows capacity increase at any time thanks to its flexibility, as well as responding to the needs of high volume production due to its continuously flowing conveyor.

As with all METWAVE Industrial Microwave Oven family, METWAVE Essentia is a digital, traceable, preventive maintenance technological machine produced with Industry 4.0 infrastructure. Thanks to its control systems, it allows different energy applications in different modules from the user interface. In this way, the desired amount of energy is applied at the desired time from the recipes recorded as the product changes, and the conveyor speed is adjusted according to the need. This provides manufacturers with optimum flexibility for seasonal, capacity or product-based changes.

In the MET Industrial Microwave Oven family, the power control panel of each module is on its own. As can be seen in detail in the photo below, these panels allow for quick maintenance and replacement. There are hoods on each module that remove the resulting moisture. Thanks to the fans on these hoods, the moisture generated by microwave energy is removed from the module by loading the air. This system, which increases efficiency when used for drying purposes, allows the most flexible control thanks to the built-in temperature and humidity sensors. Inlet air and outlet air temperatures are controlled and accordingly the fan speed can be changed digitally from the display.

The conveyor-shaped structure of the METWAVE Industrial Microwave Oven family does not occupy space like fixed and closed tunnels. It is mounted in the relevant places in the production lines and provides a regular, continuous flow. During the loading of the products to be processed, care should be taken to ensure that they are only uniformly distributed and not more than the height allowed by the microwave silencers. As can be seen from the photo below, there are guides to guide the products at the loading and exit sections. The loading of the products to be processed in the METWAVE Industrial Microwave Oven family can generally be done with a shaker provided by the customer or any stacker that provides equal surface area. The conveyor belt of the system is the highest clearance modular belt suitable for food and specially selected for the product. This modular belt is equipped with washing, brushing and drying units at the end of each cycle. This washing and drying system, which can be integrated with the oven, provides great benefit in terms of cleaning and hygiene in long-term operations.

METWAVE Essentia has a total installed power of approximately 70 kW. This value can change with the differentiation of the options to be purchased on the machine. Each module is 1.65 metres long and 1.2 metres wide. With the silencer modules at the inlet and outlet, the total length is close to 10 metres. The best opportunity provided by the modular structure is that in case of future capacity increases, modules can be added as desired and the length of the furnace can be extended. All modules and bodies are made of AISI304 stainless steel. These structures, which can also be manufactured as AISI316 upon request, provide the highest hygiene in production.

METWAVE Essentia Machine Safety:

METWAVE Industrial Microwave Oven family complies with the relevant LVD and EMC standards required by the product definition, especially the Machinery Directives determined by the European Union. The silencers at the inlet and outlet of the conveyor have a low level of microwave emission permitted by the standard and not harmful to human health. Each METWAVE Industrial Microwave Oven product is measured after installation in the field and this safety is verified. All microwave generators are externally fixed in a closed mechanical structure. This structure, which does not allow access except for access by authorised and trained personnel for maintenance, helps to protect external leaks. Observation, cleaning and intervention windows on the modules are protected by safety sensors. All safety elements on the machine are managed by a safety relay, minimising the risk of error. If desired, arc detection and emission sensors can be added to the machine for maximum protection.

Figure 3 METWAVE Essentia Loading Detail

METWAVE Essentia Usage Areas:

METWAVE Essentia Industrial Microwave Oven can be used as a performance enhancer before existing heating or cooking lines. Reduces the total energy consumed in conventional heating, cooking or other processes. Increases production efficiency. In the analyses made, it has been observed that it increases the performance of the heating line up to 25% by integrating it in front of the existing heating lines. Heating the product from the inside to the outside, which is one of the most important features of microwave heating, provides a homogeneous energy distribution and allows products to be heated at lower temperatures. Due to the conduction of heat in conventional methods, it is necessary to heat the outer shell to higher temperatures to bring the inner core to the desired temperature, especially if the heat conduction coefficient of the product is low (usually food products are quite low). This causes many problems in the product such as browning, texture deterioration, taste change, caramelisation and so on. When METWAVE Essentia Industrial Microwave Oven is used for preheating, it reduces this effect for the reasons described above.

When METWAVE Essentia Industrial Microwave Oven is used for cooking, it turns into a line that provides efficient and even cooking thanks to its flexible structure that can be controlled digitally from the user interface. It allows the desired capacity from 1 kg product to 800 kg product per hour. (The capacity depending on the weight here should be examined separately for each product, as the product shape, self-mass and energy that can be applied per unit time may be different). This system is ideal for pre-cooking, post-cooking or cooking processes of meat, fish, poultry or other foods.

Another area where METWAVE Essentia Industrial Microwave Oven can be used is tempering. Tempering in a continuous system allows precise control of other operations such as slicing, dividing, shaping and moulding of products. Product quality and production are improved and the drying effect is reduced. Flavour and protein components are retained in the product.

Metwave Essentia Advantages

MET Industrial Microwave Dryers and industrial microwave dryers that we produce specially for your business

Thanks to the drying systems, you will get a high performance efficiency.

Error Rate
Decline

Quality
Increase

Energy
Efficiency

Productivity

Product Value

Labor
Decline