21.07.2026

Dual-Fan Technology for hot smoke treatment

When Airflow Becomes a Matter of Process Reliability: The Latest Dual-Fan Technology for Hot Smoke Treatment for the U.S. Market

VETEC ANLAGENBAU from Germany combines proven AEROMAT technology with intelligent control and regulation systems to ensure uniform thermal treatment, fewer manual operating errors, reduced maintenance requirements, and greater traceability.

How do companies in the food industry ensure that hot and cold spots in their facilities are minimized through optimal airflow? How do they ensure production that complies with standards and regulations? And how can they prevent employees from making incorrect program settings that compromise maximum output per batch?
This requires state-of-the-art technology that not only controls individual parameters but also intelligently integrates the product, loading, airflow, program, and documentation.

In industrial food processing, airflow determines far more than just the process duration. It influences color, texture, core temperature, degree of drying, product yield, and ultimately the safety of the entire manufacturing process. Especially with densely loaded smoking cars, the same fundamental question arises time and again: Does the airflow truly reach every product under comparable conditions, or do zones develop where the product is over- or under-treated thermally?

USA: Meeting Stringent Safety Requirements with Smart Processes

This issue is particularly relevant in the U.S. market because food safety, the burden of proof, and liability risks play a central role. Requirements from FDA cGMP, USDA FSIS, HACCP, GFSI-aligned standards, or the Appendix A guidelines on pathogen inactivation all call for processes that can be documented and validated. For manufacturers of sausages, bacon, jerky, ham, fish, cheese, or pet food snacks, this means that it is not merely a matter of whether a system is technically capable. What matters is whether it consistently and traceably delivers the correct result.

The AEROMAT, a hot-smoking and drying system from VETEC ANLAGENBAU, is designed for a wide range of process steps, including drying, smoking, cooking, cooling, baking, and pasteurization. Products can be processed either hanging or in a lying position. However, it is precisely this distinction that significantly alters the airflow conditions on the trolley. “Hanging sausages present different air resistance than flat-laid ham. In addition, loading density is also a key factor,” explains Andreas Sauer, Managing Director of Sales at VETEC ANLAGENBAU. “Especially with varying products and loading configurations, a one-size-fits-all airflow pattern is therefore insufficient.”

Until now, VETEC has primarily relied on the proven mechanical interchangeable flap system for the classic AEROMAT. This system has been established in practice for decades and remains the standard solution for many applications. It enables circulating airflow and can be adapted to different products and trolley configurations. However, when processing many different goods with varying load configurations, the interchangeable flap system increases the amount of manual labor required. This is because every mechanical component requires maintenance: it must be inspected, adjusted, and, if necessary, readjusted. In addition, operating personnel must always know the correct software settings and apply them consistently. In large facilities with shift changes, high throughput, and variable product lines, this becomes a real risk factor.

Two Fans Instead of a Mechanical Switching System

This is exactly where VETEC’s dual-fan technology comes into play. The system uses two electrically powered fans per chamber, each controlled by a frequency converter. Instead of mechanically switching the airflow, the fans generate the desired air curtain by operating in an alternating pattern. While one fan operates at higher power, the other reduces its power accordingly.

For VETEC, the dual-fan solution is not an entirely new development; it has been used in cold-smoking applications for many years. What is new is the adaptation and intelligent integration of this principle with modern control and regulation technology for hot-smoking processes in all AEROMAT systems, including AEROMAT ^HYBRID (exception: AEROMAT ^{CROSS POWER}). “The real innovation lies not solely in the two fans,” emphasizes Andreas Sauer. “The key benefit stems rather from the interplay of electrically driven airflow control, the process program, and intelligent control.”

Automatic Product Recognition Reduces Operating Errors

At the heart of this software control system is the MICROMAT, which can be optionally supplemented by the MICROMAT ^ANALYZER: The MICROMAT ^ANALYZER monitors and documents relevant process data such as chamber temperature, humidity, flow velocity, and core and surface temperatures. This provides a technical foundation for ensuring batch-specific traceability of processes. As part of a Smart Scan process, the product trolley can optionally be equipped with a QR code, barcode, or RFID tag. Upon loading or startup, the system recognizes which product is in the system. The appropriate program is then automatically run. In the advanced version, the solution can also be connected to higher-level systems such as ERP or SCADA. If a trolley does not match the intended program, an error message is displayed.

For the operator, the process is thus reduced to just a few steps: scan, load, start. This reduces the likelihood of incorrect program settings or inconsistent operating procedures. “In industrial production, quality must not depend on who happens to be operating the machine at any given time,” says Andreas Sauer. “When the system recognizes which product is being processed and automatically executes the correct program - including airflow control - we achieve significantly greater process stability.”

The U.S. Market Values Flexibility and Productivity – Nearly 40 Systems Being Delivered

VETEC ANLAGENBAU is currently delivering nearly 40 AEROMAT systems to the U.S., featuring approximately 600 storage spaces and dual-fan technology, including integrated control and regulation automation. This demonstrates the momentum this technology is gaining here. For VETEC, North America is already a strategic core market. In this market, cost-effectiveness and availability play an important role alongside process reliability - challenges that the technology is specifically designed to address.

This is because electrically controlled fans with frequency converters can be controlled via the HMI. At the same time, flexibility increases when switching between products, since adjustments no longer need to be made physically on the equipment but are instead carried out via software. This is particularly appealing to facilities that process different product groups at high throughput rates. In a facility that produces hot dogs today, ham tomorrow, and jerky the day after, quick, low-error changeovers become a key factor in productivity. The more uniform airflow also improves product consistency and yield and shortens processing time.

State-of-the-art Technology for Reliable Results

The dual-fan solution is therefore more than just a standalone equipment option. It reflects a broader shift in thermal food processing - from isolated mechanical adjustments to integrated, product-specific, and fully traceable process systems.
For customers, this translates into greater process reliability in complex production environments. For operators, it means fewer manual interventions. For quality assurance and management, it provides more comprehensive process documentation.
“The U.S. market is looking for more than just technology - it is looking for reliable, consistent results,” summarizes Andreas Sauer. “That is exactly where our system comes into play. We combine airflow management, automation, and process expertise to help customers operate their processes more safely, more flexibly, and with a high degree of repeatability.”