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Modular Process Case Studies

EPIC Systems Installs Power-Limiting Heat Trace System

power-limiting heat traceHeat Trace Design

A consumer products company approached EPIC with the need to maintain temperatures through 250 feet of piping for a hot-fill product.

CLIENT: A Fortune 500 company

INDUSTRY: Consumer Products


    • New product line from concept stage
    • Power-limiting heat trace system
    • 250 feet of process pipe line
    • Multiple circuits to keep voltage low
    • Insulation of piping and product mixing system



    • High temperature product requirements for precision molding to container
    • Low voltage requirements for 250+ feet of piping
    • Correct insulation of process valves, pumps and flanges to prevent heat sinks



Front-end Engineering

EPIC completed its unique front-end engineering from the concept stage of the project to assure the most efficient process and accurate
cost quotation. EPIC’s engineers completed a line analysis and created an implementation plan that included the following elements:

    • Heating jacket in the mixing tank for temperature regulation
    • Power-limiting heat trace system
    • Insulation on piping and process tank
    • Multiple circuits to meet 30 amp max regulations


EPIC’s Proven Solutions

EPIC’s power-limiting electrical heating system stretches from the mixing tank to the filler. After the product is mixed and brought to temperature it enters the piping, which uses the heat trace system to maintain a liquid state. The liquid product enters the filler and is hot-filled into its container.

Some product travels through more than 250 feet of piping between the tank and the filler. Proper heat trace system function is maintained by smaller circuits which split the main circuit for voltage regulation below 30 amps across the heat trace wires. Proper insulation of the mixing tank, piping, flanges and valves prevent unintentional heat sinks from forming


    • Installed an efficient new product line
    • Ensured longevity of the line by using heat trace design best practices
    • Decreased plant construction time by installing and insulating heat trace system before piping installation



EPIC provided expert insight during the design and installation process. Due to EPIC’s experience in the field, EPIC was able to recommend the correct applications and prevent problems before they arose.

The EPIC Difference includes several key features that assure a projects success:

    • Front-End Engineering to ensure that the proper steps are taken during project scope development
    • Plant engineering experience that assists clients to identify needs, pinpoint objectives and provide the most appropriate manufacturing equipment for the application
    • Open door client policy to promote innovation. We invite clients to visit EPIC to experiment with new processes, technologies and techniques that push the limits of traditional engineering.
    • Accountability to responsibly manage our clients’ projects from start-to-finish and beyond.
    • A transfer of knowledge (not just a basic training) for the systems and equipment we provide
    • Single point of direct contact during the entirety of the project
    • State-of-the-art shop which decreases down-time and increases the speed of project completion


Find a solution that is right for your company. Contact EPIC or learn more about electric heat trace design.

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EPIC Modular Process Systems
4134 Meramec Bottom Rd
St. Louis, MO 63129, US
(314) 845-0077

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