Technical specifications to match your needs

Operational efficiency and better profit margins start with technical specifications that exactly suit your business. That’s why our approach always starts with asking what you need to succeed.

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What you can expect from PTL melters

On average, our customers get excellent ROI on any investment in PTL melters. That’s because every machine is customed-designed to your needs with our thirty years of experience.

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Services required

PTL melters only require power, air and water.

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Safe, simple toolless changeovers

The melters are designed to make changeovers fast and simple, without needing tools

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Designed for simplicity

Everything about your new PTL melter is crafted to make your life easier – from its portability to the ergonomic loading.

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Powerful: 125% higher melt rates

The revolutionary design delivers instant melting and continuous process supply to increase downstream production without large tanks.

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Compact: Significantly smaller footprint

Self-contained and compact, your melter can be located next to use point to avoid long pipe runs.

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Flexible: changeovers transformed

Make it easier to switch masses/coatings fast, with a removable met grid, washdown design and fast simple cleaning.

Seamless installations and startups

Our team have the expertise and process experience to ensure installation and start up goes without a hitch.

Project planning and management

With our expert team involved in the project planning, execution and installation, you’ll know you’re covered for all the requirements and considerations.

Access to technical expertise

Get fast answers to your questions from our responsive technical team – they know our melters and they know your business.

Training and ongoing support

Upskill your team and realize full ROI faster with training and ongoing support from PTL.

Specifications

Use the table below to estimate possible melt rates of chips or buttons and blocks – from small (10lbs) to one-ton. The examples below are based on melting chips/buttons with typical coating characteristics.

	S1	S3	D3
Footprint	66.92" x 46.85" (1700 x 1190mm)	91.46" x 80.71" (2323 x 2050mm)	157.48" x 80.71" (4000 x 2050mm)
Melt rate range	Up to 1100 Ib/hr (500 kg/hr) (Product dependent)	Up to 3190 Ib/hr (1450 kg/hr) (Product dependent)	Up to 6380 Ib/hr (2900 kg/hr) (Product dependent)
KW/Heating capacity	Up to 36 KW	Up to 36 KW	Up to 72 KW
Priming time (this is the time from when product is loaded into the melter to the point where the product level in the tank is above the outlet port)	15-20 minutes
Typical cleaning time (this incudes both a hot water wash down with detergent and hand cleaning as required, followed by the time for the machine to dry ready for the next product)	3 hours	3.5 hours	5 hours

	S1	S3	D3
Footprint	66.92" x 46.85" (1700 x 1190mm)	91.46" x 80.71" (2323 x 2050mm)	157.48" x 80.71" (4000 x 2050mm)
Melter rate range	Up to: 1100 lb/hr (500kg/hr) (product dependent)	Up to: 3190 lb/hr (1450kg/hr) (product dependent)	Up to: 6380 lb/hr (2900kg/hr) (product dependent)
KW/heating capacity	Up to 36KW	Up to 36KW	Up to 72KW
Priming time (This is the time from when product is loaded into the melter to the point where the product level in the tank is above the outlet port)	15-20 mins
Typical cleaning time (This includes both a hot water wash down with detergent and hand cleaning as required followed by the time for the machine to dry ready for the next product)	3 hours	3.5 hours	5 hours

FAQ

1. What is the cleaning / changeover procedure:

Remove the melt head onto the wash down trolley.
Scrape down tank and stirrer to remove any bulk build up of product. Use the quick access stirrer seal removal to make this simpler.
Use a high-pressure hot water hose to hose down inside all product-contact areas.
Turn the stirrer by hand, once the seal is removed.
Hose melt head in the washroom.
Carry out sanitizing procedures.
Reassemble the machine and turn the heating back on for faster drying.

2: What is the maximum allowable temperature to melt and maintain the product at?

It can melt product at any temperature up to 80C (175F). Melted product in the hold tank below can also be maintained at temperatures of up to 60C (140F).

3: What is the time delay from machine start-up to production, i.e. time for the system to heat up ready for use?

It takes approximately 40 minutes to heat up. The product can be used as soon as the volume of melted product is above the pump suction outlet, and there is enough to fill the process system.

4: Can I connect the melter to an existing product pipeline in our factory?

Yes, the product outlet will connect to existing process equipment (with a triclover or your preferred connection). The melter also includes a triclover connection at the rear of the tank for product return to the melter, if required.

5: Do you offer any downstream process equipment to connect to this, e.g. product pipeline, process pump?

Yes, we offer several types of product delivery systems from the melter to your existing equipment. These include product filters and magnets, pumps, jacketed pipelines and sieve systems.

6: How long will it take to train new factory employees to use the melter?

The operation and changeover tasks on the melter are simple and intuitive, which allows factory workers to operate the machine after a short training session. PTL provide detailed instructions on the melter functions, and we also provide on-going support for your machine when needed.

7: How many workers are needed to operate and/or clean this machine?

For normal operation, you’ll only need one worker to load product onto the grid and / or adjust the machine settings. We recommend having two workers available during changeover of the melt-grid and removal of the stirrer.

8: Are there any difficult-to-reach areas, or laminate faces, that prevent the machine being fully allergen cleaned?

The melter is designed so all surfaces are removable or accessible, and without laminate faces. It has removable components to improve cleanability and enable you to meet strict allergen requirements. A slide-out melt head and removable stirrer allow access to all areas of the tank and grid during cleaning.

9: Can I customise the size and shape of the machine to suit my factory requirements?

We offer three standard sizes of the melter V20 (S1, S3 and D3), but if these don’t suit your requirements, please get in touch to discuss custom options.

10: What is the tank volume?

S3-V20 = Tank volume is 445 litres / 535 kg chocolate.

Other sizes confirm on request.

11: Are the tank and melt grid separate heating controls?

Yes, they are independent control zones.

12: What over-temperature protection is in place?

The water heating has a safety cut out temperature setting for both zones.

13: What feed/loading options are available?

Bulk bag gantry for gravity feed of wafers from super sacks
Bulk tote dumping stations and feeding conveyors for wafers from totes or bulk drums
Bag dump stations and feeding conveyors for wafers from boxes and bags
Manual loading

14: What is the advantage of a PTL melter over a kettle?

It has a much smaller foot-print, but provides more power, faster priming, increased flexibility, easier access for cleaning and better availability of molten product. It’s portable, so you can also locate it next to the use point.

15: Will the holding tank overflow if it’s already full and there is product still on the melt grid?

No. The tank high level sensor will shut down the melt grid heating at the selected height.

16: Is the electric water heating system included as standard?

Yes. We can also use other heat sources if preferred, such as gas, plant hot water, and steam.

17: What products can we melt in the V20?

The melter is specifically designed for chocolate and compound chips/wafer/buttons and small blocks. However you can also melt cocoa liquor, cocoa butter, shortening and other fats in small and large block (up to 1 ton block) form. We would use the V20 or a block melter depending on the application.