Microwave Heating in Industrial Settings

Authors Name: Hope Baxter


Microwave heating was discovered accidentally during the development of radar when Percy Spencer, an engineer at Raytheon, noticed that his candy bar melted in his pocket whenever a radar set was activated. Unlike other forms of heating that have to first penetrate the surface of a solid and then work its way inside, microwave heating evenly distributes the electromagnetic waves to heat evenly throughout. This is why microwave heating is known for its ability to heat things rapidly.

We know microwave heating has a place in the kitchen, but after its development into a cost efficient way to heat things quickly, microwave ovens found themselves in other industrial applications. Heating in industrial processes is not new, and in some cases, using a microwave oven might be overkill. But consider the following and you too will see the usefulness of microwaves in the industrial workplace:

Even distribution of heat

Electromagnetic waves, which categorize what microwaves are, are energy that can penetrate objects thoroughly and evenly. When using other forms of heat such as convection, the heat source first heats up the air. This heated air is enclosed with the object to be heated and the heat is then transferred to the surface of this object. Energy is expended to heat the object from the outside-in.

In certain cases, such as when working with ceramics for sensors or semi-conductors, this may not be desirable at all. The insides get “undercooked” while the outside may be overly “well done.” An uneven distribution of heat may cause design flaws, fractures, or other imperfects to form. When imperfections form in ceramics used in sensors, for instance, this may cause the sensor to fail prematurely, or even not function at all. By using the penetrating energy of microwaves, objects are heated evenly. Heating using radiation from microwaves becomes vastly superior to heating through convection.

Quality of product is increased

As stated above, now that even distribution of heat can occur, the quality of the product is maintained. Components have fewer defects. MTBF is increased because fewer deformities and fewer imperfections manifest in the components produced. Cosmetically, the chances of a product “looking better” are also increased.

If your company produces automotive parts, you can use microwave heating in your process heating and create a more reliable product. While the equipment might seem harder to maintain and more expensive that a convection oven, for instance, you make the money back in increased business. Lower MTBF, fewer defects per components manufactured, and an overall better product will assure that you will supply your vendor with the parts he or she is looking for consistently.

More efficient than standard ovens

Also related to the above points is the fact that microwave technology is efficient in creating heat. You can keep costs low by heating your components faster, pushing more through the assembly line process. Also, there is less set up time as you don’t have to “fire up” the oven at the start of the day and then turn it off at the end of the shift. Energy is used to heat the component, part, or product evenly.

No time is wasted on heat transference that is ultimately not going to heat your product all the way through. Most of the energy is used for the purpose of heating and is not lost. This helps to keep costs low, especially if you are in a highly competitive field in which components are produced by many suppliers. The faster you get your products out there and the lower you keep your costs, the better your chances of attaining a higher margin.

There are certain things to consider before making a change from conventional heating to microwave heating:

# Cost: Cost does not only assume the cost from making the switch. Will making the switch end up paying for itself within a reasonable amount of time? Will it increase your output, make better products, and keep costs low? A cost analysis should be performed before purchasing the equipment. While microwaves ovens are reliable, they are a major investment.

# Industry Standards: If you have a highly competitive industry that does not use microwave heating, and the quality of products varies, this might make you stand out as a reliable supplier capable of fast and voluminous output.

Once these factors are considered, you can make a better decision about employing microwave heating into your production process. Though the discovery of microwave energy’s ability to heat objects was accidental, it revolutionized the process by making it faster, efficient, and more reliable. It might be time to consider employing microwave heating into your processes.