Bulletin 820
Ultra~CPA CRITICAL PROCESS AIR UNIT The food industry historically has viewed critical process air-handling units as a key component in the refrigeration system but not a part of the Process Room. However, this is changing rapidly as equipment hygiene, designs for effective cleaning and food safety awareness increase. Today, a growing number of food processors consider the critical process air unit as an integral part of their production process and view them as a key piece of processing equipment. As a result, there is much greater emphasis on the internal construction of the unit and the ability to efficiently clean and fully inspect the equipment. These critical process air handling units must be designed to eliminate all internal areas where bacteria and other contaminants can accumulate and areas which are not readily accessible during the cleaning process. This increased emphasis on hygiene and sanitation dictates a totally new vision of how to design the interior structure and key components of the air handler; as well as, new techniques used to manufacture the equipment. EVAPCO s new Ultra~CPA System has been designed to meet the needs of today s most demanding food processing companies. As the next generation of critical process air handling units, the Ultra~CPA System is capable of handling full wash-down mode. The unit incorporates fully welded and pitched stainless steel drain pan systems. The welds are smooth and nonporous. The drain connections are fully recessed to facilitate complete drainage in all sections. The interior walls are designed to be flush with the edge of the drain pan to eliminate flat surfaces between the base of the interior walls and the top of the drain pan. The interior walls are designed to eliminate all exposed fasteners, even where the closures meet the wall. Ultra~CPA System STAINLESS STEEL DRAIN PAN Typically, interior components of the air handler are supported and mounted in a manner which does not provide complete accessibility for cleaning. For example, in conventional air handlers the heating and cooling coils are mounted on the floor using fabricated steel hat channels. This common design method results in a solid structure for supporting the coil. However, it makes the areas below and adjacent to the coil supports virtually impossible to clean and inspect. Even though there are drain pans under the coil, there is still not sufficient room to clean directly beneath the coil or under the support channels. TRADITIONAL COIL SUPPORT DIFFICULT TO CLEAN The Ultra~CPA System has a re-designed coil support system that makes cleaning under the coil both easy and efficient. There are no longer open structural steel supports under the coil which obstruct the cleaning and inspection process. The new closed coil support system eliminates hidden areas, while providing full visibility and access to the coil supports and surrounding areas for maximum cleaning efficiency.
In a conventional air handler, the design of the blower and motor section make it especially difficult to access and clean. Support channels, bracing, angles and other obstructions mounted to the floor of the unit make cleaning and sanitizing virtually impossible. Regardless of the number of blowers, these standard methods of installation create a real challenge for proper cleaning and sanitizing of the unit. As with the cooling and heating coils, a radical re-design which enables for full access under these components was necessary. The Ultra~CPA System incorporates a unique closed structural support system that completely eliminates the traditional support and framing around and under the blower. Ultra~CPA System BLOWER AND MOTOR PRECISION BALANCED FOR EFFICIENT OPERATION This revolutionary design makes the area under the blower and motor completely open, making cleaning and inspection simple and efficient. In addition, the Ultra~CPA System utilizes direct drive aluminum blowers. This blower design eliminates belts and the associated cleaning, maintenance and dust issues. The use of Variable Frequency Drives in the Ultra~CPA System will result in efficient fan operation, precision balancing of the system and maximum energy savings. TRADITIONAL BLOWER/ MOTORMOUNT DESIGN Ultra~CPA System CLEANING UNDER THE COIL IS EASY AND EFFICIENT
Another area often overlooked with conventional air handling systems is the lack of sufficient interior lighting for proper cleaning and inspection. The Ultra~CPA System is designed with hygienic/food grade, waterproof lights which allow for excellent visual inspection of the inside of the unit. In addition, the lights are hung from the ceiling with a specially designed offset so the light and its mounting system are easy to clean and inspect. Ultra~CPA System HYGIENIC, FOOD GRADE, WATERPROOF LIGHTS Universal, off-the-shelf filter frames are typically used in the air handling industry. They are versatile, easy to install and can be used for almost any type of filter. However, these stock filter frames are very difficult, if not impossible to clean and maintain. Their universal design requires multiple hold/pinch points, different filter clips, and numerous joints and crevices between the individual frames. The Ultra~CPA System addresses this design issue by incorporating custom designed, solid-welded filter frames designed without holes, joints, clips and pinch points. This filter frame design provides a simple, clean and sanitary mounting method for any type of filter. In addition, the frames have no gaskets. The gaskets are located on the filters which result in a new, air tight gasket every time the filter is changed. Air dampers are commonly used in air handlers. Their multi-piece blade assembly and linkage design offer numerous challenges for cleaning personnel. The typical dampers use air foil blades which are hollow on the inside. As a result, they are very difficult to inspect and clean. Also, most standard dampers have a channel frame construction which forms a pan on the top of the assembly making this area impossible to clean. Ultra~CPA System air dampers use a single blade design with removable gasket. The top of the assembly is open for easy cleaning. This design eliminates the possibility of collecting water or contaminants on the dampers. TRADITIONAL UNIVERSAL FILTER FRAMES Ultra~CPA System CUSTOM SOLID WELDED FILTER FRAME Ultra~CPA System SINGLE BLADE DAMPER ASSEMBLY
Ultra~CPA CRITICAL PROCESS AIR UNIT Effective cleaning of the heating and cooling coils is another parameter which EVAPCO has addressed in the Ultra~CPA System. Heating and cooling coils are maintained in clean and contaminant free condition with the exclusive EVAPCO Sanitizing System (ESS). The ESS uses the latest high output UVC emitter technology to effectively eradicate mold and other contaminants right at the source. Properly installed and maintained ESS UVC lights will eliminate the need for coil sanitizing or cleaning. However, should coil cleaning be required, it can be safely performed without removing the UVC lights which are 100% watertight. The casing walls of the Ultra~CPA System are manufactured with heavy gauge double wall construction for long equipment life. Casing walls are ESS UVC LIGHT SYSTEM foamed in place for maximum insulation resulting in a single piece, unitary construction with no through metal design. The Ultra~CPA System has been precisely engineered to be the penultimate hygienic, critical process air system in the Food and Beverage market. In fact, every aspect of the unit s sanitary design has been addressed including the use of acorn nuts on the few fasteners that are in the unit, resulting in no exposed fastener threads for contaminants to collect! NO EXPOSED THREADS FULLY FORMED AS ONE SINGLE PIECE Ultra~CPA Systems are offered with an open platform PLC control system. This control system enables the End-user to specify the exact control sequence for the system and the specific monitoring requirements for the project. The open platform PLC control offers maximum system control flexibility, especially when compared to closed design, micro-processor control systems used by other manufacturers. The Ultra~CPA System is just not a typical critical process air handling unit. It is the NEXT GENERATION of sanitary critical process air handling systems offered for today s most demanding Food and Beverage Processors. OPEN PLATFORM PLC CONTROL PANEL
SUPERIOR PRODUCTS FROM SUPERIOR TECHNOLOGY THE FUTURE IS NOW WITH THE Ultra~CPA SYSTEM... NOT YOUR TRADITIONAL AIR HANDLER... THE Ultra~CPA IS THE ULTIMATE CRITICAL PROCESS AIR SYSTEM! EVAPCO North America EVAPCO, Inc. World Headquarters P.O. Box 1300 Westminster, MD 21158 USA Phone: 410-756-2600 Fax: 410-756-6450 E-mail: marketing@evapco.com EVAPCO East 5151 Allendale Lane Taneytown, MD 21787 USA Phone: 410-756-2600 Fax: 410-756-6450 E-mail: marketing@evapco.com EVAPCO Midwest 1723 York Road Greenup, IL 62428 USA Phone: 217-923-3431 Fax: 217-923-3300 E-mail: evapcomw@evapcomw.com EVAPCO West 1900 West Almond Avenue Madera, CA 93637 USA Phone: 559-673-2207 Fax: 559-673-2378 E-mail: contact@evapcowest.com EVAPCO Iowa 925 Quality Drive Lake View, IA 51450 USA Phone: 712-657-3223 Fax: 712-657-3226 EVAPCO Iowa Sales & Engineering 215 1st Street, NE P.O. Box 88 Medford, MN 55049 USA Phone: 507-446-8005 Fax: 507-446-8239 E-mail: evapcomn@evapcomn.com EVAPCO, Inc. World Headquarters & Research/Development Center EVAPCO, Inc. P.O. Box 1300 Westminster, MD 21158 USA PHONE: 410-756-2600 FAX: 410-756-6450 E-MAIL: marketing@evapco.com EVAPCO Newton 701 East Jourdan Street Newton, IL 62448 USA Phone: 618-783-3433 Fax: 618-783-3499 E-mail: evapcomw@evapcomw.com EVAPCO-BLCT Dry Cooling, Inc. 981 US Highway 22 West Bridgewater, New Jersey 08807 USA Phone: 1-908-379-2665 E-mail: info@evapco-blct.com Refrigeration Valves & Systems Corporation 1520 Crosswind Dr. Bryan, TX 77808 USA Phone: 979-778-0095 Fax: 979-778-0030 E-mail: rvs@rvscorp.com McCormack Coil Company, Inc. P.O. Box 1727 6333 S.W. Lakeview Boulevard Lake Oswego, OR 97035 USA Phone: 503-639-2137 Fax: 503-639-1800 E-mail: mail@mmccoil.com EvapTech, Inc. 8331 Nieman Road Lenexa, KS 66214 USA Phone: 913-322-5165 Fax: 913-322-5166 E-mail: marketing@evaptech.com Tower Components, Inc. 5960 US HWY 64E Ramseur, NC 27316 Phone: 336-824-2102 Fax: 336-824-2190 E-mail: mail@towercomponentsinc.com EVAPCO Europe EVAPCO Europe, N.V. European Headquarters Industrieterrein Oost 4010 3700 Tongeren, Belgium Phone: (32) 12-395029 Fax: (32) 12-238527 E-mail: evapco.europe@evapco.be EVAPCO Europe, S.r.l. Via Ciro Menotti 10 I-20017 Passirana di Rho Milan, Italy Phone: (39) 02-939-9041 Fax: (39) 02-935-00840 E-mail: evapcoeurope@evapco.it EVAPCO Europe, S.r.l. Via Dosso 2 23020 Piateda Sondrio, Italy EVAPCO Europe, GmbH Bovert 22 D-40670 Meerbusch, Germany Phone: (49) 2159-69560 Fax: (49) 2159-695611 E-mail: info@evapco.de Flex coil a/s Knøsgårdvej 115 DK-9440 Aabybro Denmark Phone: (45) 9824 4999 Fax: (45) 9824 4990 E-mail: info@flexcoil.dk EVAPCO S.A. (Pty.) Ltd. A licensed manufacturer of EVAPCO, Inc. 18 Quality Road Isando 1600 Republic of South Africa Phone: (27) 11-392-6630 Fax: (27) 11-392-6615 E-mail: evapco@evapco.co.za Evap Egypt Engineering Industries Co. A licensed manufacturer of EVAPCO, Inc. 5 El Nasr Road Nasr City, Cairo, Egypt Phone: 2 02 24022866 /2 02 24044997 Fax: 2 02 24044667/2 02 24044668 E-mail: Primacool@link.net / Shady@primacool.net EVAPCO Asia/Pacific EVAPCO...SPECIALISTS IN HEAT TRANSFER PRODUCTS AND SERVICES. Visit EVAPCO s Website at: http://www.evapco.com EVAPCO Asia/Pacific Headquarters 1159 Luoning Rd. Baoshan Industrial Zone Shanghai, P. R. China, Postal Code: 200949 Phone: (86) 21-6687-7786 Fax: (86) 21-6687-7008 E-mail: marketing@evapcochina.com EVAPCO (Shanghai) Refrigeration Equipment Co., Ltd. 1159 Louning Rd., Baoshan Industrial Zone Shanghai, P.R. China, Postal Code: 200949 Phone: (86) 21-6687-7786 Fax: (86) 21-6687-7008 E-mail: marketing@evapcochina.com Beijing EVAPCO Refrigeration Equipment Co., Ltd. Yan Qi Industrial Development District Huai Rou County Beijing, P.R. China, Postal Code: 101407 Phone: (86) 10 6166-7238 Fax: (86) 10 6166-7395 E-mail: evapcobj@evapcochina.com EVAPCO Australia (Pty.) Ltd. 34-42 Melbourne Road P.O. Box 436 Riverstone, N.S.W. Australia 2765 Phone: (61) 2 9627-3322 Fax: (61) 2 9627-1715 E-mail: sales@evapco.com.au EVAPCO Composites Sdn. Bhd No. 70 (Lot 1289) Jalan Industri 2/3 Rawang Integrated Industrial Park Rawang, Selangor, 48000 Malaysia Phone: 60 3 6092-2209 Fax: 60 3 6092-2210 EvapTech Asia Pacific Sdn. Bhd A wholly owned subsidiary of EvapTech, Inc. IOI Business Park, 2/F Unit 20 Persiaran Puchong Jaya Selatan Bandar Puchong Jaya, 47170 Puchong, Selangor, Malaysia Phone: (60-3) 8070-7255 Fax: (60-3) 8070-5731 E-mail: marketing-ap@evaptech.com 2M/4-12/DGD Bulletin 820 2012 EVAPCO, Inc.