Custom Electric Fryer Revamp for Production-Scale Testing
Engineering a Smarter Fryer: Ramco + Tempco's Scalable Heating Redesign
When a leading food equipment manufacturer needed to simulate production-scale frying in a test lab, they turned to Ramco for a high-powered, reliable solution. It had been over 15 years since the original gas-fired fryer project, and the team was ready to take a fresh, more efficient approach. The system was developed for a food manufacturer that mass-produces fried chicken for freezer packaging and distribution.
The Challenge: Revisiting an Old Design
The original design of the machine utilized a gas-fired heat exchanger, which had proven inefficient and unreliable at lower production rates. Downtime became an insurmountable problem since the system had persistent weld quality issues and premature element failure.
After a decade and a half, the equipment needed a significant upgrade, but the long gap between projects meant many details were lost to time. Ramco's Kansas City team, led by Doug Lybarger, consulted directly with several engineers to piece together the root causes of previous failures and map out a migration path.
The Solution: Electric Immersion Heating at Scale
Working closely with Tempco, a leader in custom heating technology, Ramco delivered a revamped design using an 80,000-watt electric immersion heater grid submerged in oil. Tempco engineered and manufactured both the heating elements and the structural support frame, delivering not only the hardware but a turnkey design package—including a 3D file to assist with pre-sale engineering review and installation planning.
This second-generation system was engineered for performance and reliability, featuring:
- 80,000 watts of electric immersion heating power for rapid oil heat-up and consistent thermal output.
- A compact footprint while maintaining the ability to process hundreds of tons of food per hour.
- Improved durability, eliminating the weld and thermal stress issues that plagued the previous system.
The Result: Scalable Test-Line Performance
Thanks to Tempco’s precision engineering and Ramco’s project leadership, the OEM now operates a powerful, production-grade fryer in a controlled test lab environment—without the energy waste and performance limitations of gas-fired systems.
This redesigned electric fryer allows for:
- Scalable testing that mirrors full production environments.
- Increased energy efficiency at low and high throughput rates.
- Reliable heating performance with robust build quality and minimal maintenance.
Why It Matters
This project exemplifies how strategic collaboration and modern thermal technologies can overcome legacy design limitations. By rethinking the heating method, the customer now benefits from a cost-efficient, scalable, and reliable testing solution that mirrors real-world production.
Ramco and Tempco proved that even 15 years later, thoughtful engineering and deep application knowledge can transform old challenges into modern wins.