Semi-Automated Mushroom Substrate Processing System, (2) 37 cu.ft Patterson All-Weld mixers, Reimers steam boiler, 120-gallon hot water tank, Cascade Heat Exchangers

used semi-automated mushroom substrate processing system. integrates high-performance components to efficiently manage pasteurization, cooling, inoculation, and packaging all within a single vessel. two jacketed patterson all-weld paddle mixers (37 cubic feet each) operate simultaneously to blend substrate ingredients uniformly while maintaining controlled processing conditions. substrate moisture content is controlled using a water metering sensor (fd-q20c) and circulating pump, which measures amount of water added from a 120-gallon (a.o. smith) hot water tank into the substrate. the mixers heat the substrate up to 98c through their closed loop hydronic heating jackets. the reimers (rhc-360) electric steam boiler feeds steam to the cascade flow control solutions heat exchanger (263450-004) which heats the hydronic jacket loop. a steam actuating valve (sterlco d151-f) modulates steam flow from the boiler, maintaining optimal jacket temperatures and pressure needed to reliably pasteurize substrate. after pasteurization, the substrate is cooled via the jackets which are isolated and chilled through a two-stage thermaline heat exchanger (t8 s-20). the first cooling stage transfers substrate heat to municipal water. the heated municipal water is collected in the 120 gallon water tank for later use in substrate hydration. the second cooling stage uses glycol chilled by a g&d 10 hp (gd-10h-ht) unit to rapidly reduce substrate temperature for inoculation. inoculation is performed through a hatch under sterile air science flow hoods (36" and 24"), providing clean, positive-pressure air to prevent contamination. substrate packaging takes place at the bottom of each vessel through an 8" pneumatic actuating valve in unicorn bags, long tubes, or by connection to another system. mixer #2 uses a spartan controls automated control package to manage processing parameters like mixing, heating, cooling, and packaging via integrated sensors and pneumatic valves. mixer #1 is manually operated. sterile air filters from davis controls maintain sterile positive-pressure conditions in the mixers throughout the entire process. the steam and hydronic system include axiom dmf-300 and cbf-2 chemical dosing units to maintain system pressure, fluid levels, and chemical treatment of jacket water. supporting components including solenoid valves, expansion tanks, gauges, and pipework in steel, stainless, brass, copper, and pex ensures durability and resistance to temperature fluctuations. boiler chemicals in the heating loop and inhibited glycol in the chilling loop protect the system from oxidation. the integrated system enables efficient, scalable, and consistent production of high-quality mushroom substrate with reduced labor cost and precise control over all critical processing parameters.