Why uniform temperature matters in food ingredient processing

Key thermal challenges in handling free-flowing food ingredients and how to solve them 

Author: Jamie Zachary 

Temperature control is an important part of food processing. Ingredients such as sugar, salt, grains and cereals all need to be heated or cooled in ways that preserve quality, avoid degradation and ensure food safety.  

The risk of improper temperature control is significant. Inadequate heating or cooling commonly leads to issues such as moisture entrapment, clumping, degradation of functional properties or even microbial risk that impact both product quality and customer safety.  

Yet keeping temperature consistent is much easier said than done. That’s why it’s essential to have a deeper understanding of which thermal processing equipment is best equipped to handle your food processing needs. 

Precision that preserves product integrity 

Free-flowing solids are typically handled in bulk quantities before being stored for extended periods. In the absence of proper temperature control of these bulk materials, various issues can arise. 

For example, insufficient cooling can lead to moisture absorption from the ambient air. This increases the risk of clumping and mold formation, resulting in a degradation of product quality.  

Furthermore, uneven temperature profiles can cause water to migrate into the product stack, with the risk of caking in these areas. A product that is too hot can also harm downstream handling, packaging and/or mixing.  

“Uniform temperature is not just about process control. It is about maintaining the integrity of your product,” says Jean-Marc Reichling, Global Sales Director at Solex Thermal Science.  

“In an industry where even small variations can impact taste, texture or performance, having tight control over every parameter makes a measurable difference.” 

Where indirect heat exchange makes the difference 

Traditional thermal processing systems such as rotary drums or fluid beds rely on direct contact with heated or cooled air. While effective in some cases, they can create hot spots or uneven temperature zones – especially in dense, granular products. 

Solex’s indirect heat exchange technology offers a more controlled alternative. Our moving bed heat exchangers (MBHEs) use a vertical, gravity-fed flow of material between a series of heated or cooled plates. The result is slow, consistent movement that allows for uniform heat transfer without the turbulence or dust generation seen in direct-contact systems. 

In our indirect cooling method, water is used as the cooling medium. The absence of air reduces the risk of contamination and maintains the hygiene standards essential for food applications. 

“This makes it an ideal fit for a wide range of food-grade materials such as sugar, salt and various grains and beans,” says Reichling. 

Spotlight on sugar: Temperature uniformity matters 

Sugar is one of the most common and most sensitive food ingredients when it comes to thermal processing. Whether you are refining, drying or cooling, uniform and consistent heat transfer is essential to preserve colour, prevent clumping and maintain crystal structure.  

Small temperature variations, especially in high-volume production, can produce inconsistent moisture removal or hot spots that compromise both product quality and shelf life. 

For example, although yellowing can be a sign of thermal damage or overheating, it is also frequently the result of uneven temperature distribution. In these cases, some particles are exposed to more heat than others. This is especially common in systems where air is used to cool or dry sugar, and control over airflow or residence time is inconsistent. Such conditions can cause certain sugar crystals to caramelize or degrade, leading to visible discoloration. 

Uniform temperature management helps mitigate this by ensuring all particles experience the same thermal environment.  

Solex has worked with sugar processors globally to implement indirect conditioning and cooling solutions that meet strict hygiene standards, while also delivering on energy efficiency and product quality. 

Our MBHEs gently cool sugar by guiding it in a slow, uniform descent between hollow plates filled with circulating heat transfer fluid. This allows for precise control, ensuring each sugar crystal is treated the same without direct exposure to air, gas or other contaminants. 

“Sugar is hygroscopic by nature, so any inconsistency in temperature control, especially during cooling, can quickly lead to operational issues,” explains Jill Caskey, Global Sales Director at Solex.  

“Our technology allows processors to cool sugar gently and uniformly, helping to reduce product loss and improve storage stability.” 

Caskey adds that uniform temperature does not just protect product integrity. It also supports better energy management. When heat is distributed evenly, the process becomes more efficient, with less over-processing and fewer adjustments needed to hit target temperatures. 

“This aligns with growing industry efforts to recover energy and reduce waste, helping food processors meet internal sustainability goals and stay ahead of emerging regulations focused on energy and emissions,” she says. 

Curious how a Solex moving bed heat exchanger can help you achieve consistent temperature control for food ingredients such as sugar, salt and grains? Visit our Food Products page to learn how we’re supporting processors around the world with proven, energy-efficient thermal solutions. 

Or, contact us today to speak with one of our heat exchange experts.