Dr. Eduard Neufeld
CEO"The in-room humidification system ensures homogeneous humidification and reliable compliance with the required standard climate in all rooms thanks to the individual units."
Benefits
Managing humidity to prevent evaporation has many benefits
Improved yields
Products retain their mass providing greater sales value when sold by weight.
Enhanced quality
Materials that retain their original moisture content maintain integrity and quality.
Improved profits
Less waste, better quality and increased yield all result in more profits.
Using humidity to prevent evaporative losses
Using humidifiers to create a moisture balance
Organic materials have an internal moisture content and will lose moisture to the atmosphere when exposed to air with a low humidity. Humidifiers are used to create an environment with perfect balance between the material’s internal moisture content and the air’s relative humidity. At this ideal level, moisture movement from the material is inhibited.
This ideal air humidity level for a material is called the equilibrium relative humidity (ERH). Different materials will have different ERHs and even the same material can have varying ERH needs, depending on its own internal moisture content. To determine a material's ERH, sorption isotherm charts are used. These charts plot material-specific ERHs at varying levels of internal moisture content for the product in question.
This ideal air humidity level for a material is called the equilibrium relative humidity (ERH). Different materials will have different ERHs and even the same material can have varying ERH needs, depending on its own internal moisture content. To determine a material's ERH, sorption isotherm charts are used. These charts plot material-specific ERHs at varying levels of internal moisture content for the product in question.
Temperature’s impact on ERH and moisture movement
A material’s temperature in relation to its environment has a significant impact on ERH and moisture movement. When a product’s temperature is greater than its environment, the potential for evaporation is increased. This is due to the heating effect the product has on the air adjacent to its surface and the resultant drop in relative humidity inside this micro-climate. The greater the temperature difference between material and the air, the greater this effect.
Conversely, if a product is colder than its environment, the potential for condensation and absorption of moisture by the material is increased. This can be seen most obviously when condensation forms on a cold glass on a hot day. But the effect is the same on chilled materials such as powders, paper or food stuffs. A low temperature and higher relative humidity by cold surfaces increases the risk of moisture movement into the material from the air.
If there is an unavoidable temperature difference between the air and materials sensitive to moisture, it's important to closely control the humidity levels. This might mean increasing humidity to keep cooked foods or freshly harvested warm products from drying out or lowering humidity to prevent chilled items from reaching dew point and developing condensation.
Conversely, if a product is colder than its environment, the potential for condensation and absorption of moisture by the material is increased. This can be seen most obviously when condensation forms on a cold glass on a hot day. But the effect is the same on chilled materials such as powders, paper or food stuffs. A low temperature and higher relative humidity by cold surfaces increases the risk of moisture movement into the material from the air.
If there is an unavoidable temperature difference between the air and materials sensitive to moisture, it's important to closely control the humidity levels. This might mean increasing humidity to keep cooked foods or freshly harvested warm products from drying out or lowering humidity to prevent chilled items from reaching dew point and developing condensation.
Improving profitability by maintaining humidity
Investing in humidification to prevent evaporative losses can offer significant financial rewards. By maintaining the ideal humidity level, moisture is retained in the materials being processed or stored. This has an immediate impact on profits for any product sold by weight, as there is simply more product to sell. A decrease in evaporative losses of 2% can represent an immediate 2% increase in profit.
For manufacturers who deliver orders by weight, preventing evaporative loss will mean less raw materials are needed for a specific quantity of end product. This can also result in faster production and therefore lower energy bills.
Quality is often improved by preventing evaporative losses. Food produce will stay fresher with a longer shelf life. Materials such as paper or textiles retain their integrity and elasticity, so behave better during manufacturing and result in better quality product. Processes may also be enhanced with materials that have higher moisture content, leading to improved reactions or flavours, and a higher market value.
For manufacturers who deliver orders by weight, preventing evaporative loss will mean less raw materials are needed for a specific quantity of end product. This can also result in faster production and therefore lower energy bills.
Quality is often improved by preventing evaporative losses. Food produce will stay fresher with a longer shelf life. Materials such as paper or textiles retain their integrity and elasticity, so behave better during manufacturing and result in better quality product. Processes may also be enhanced with materials that have higher moisture content, leading to improved reactions or flavours, and a higher market value.
Preventing evaporative loss is beneficial in many industries
Discover Condair in action
Fogra Forschungsinstitut für Medientechnologien e.V., Aschheim (Germany)
In-room humidification ensures controlled humidity in the printing room. This guarantees a standard climate for the reliable testing of identity cards and banknotes.
Mondi Group, Sonneberg (Germany)
The Mondi Group is a manufacturer of paper-based packaging made of corrugated and solid board. More than 3,000 employees in 15 plants at a total of 13 European locations produce individual packaging solutions in all required sizes and finished in a wide variety of ways.
WERNER KENKEL Sp. z o.o., Krzycko Wielkie (Poland)
For packaging manufacturer Werner Kenkel, controlled humidity has a direct impact on production and quality assurance. More speed, consistent quality and less waste are the most important advantages.
BluePrint AG, München (Germany)
To protect against electrostatic charges, BluePrint uses energy-saving in-room humidification with high-pressure nozzles from Condair.
Bart Sp. z o.o, Åšwiecie (Poland)
The packaging specialist Bart Sp. z o.o not only ensures the quality of its products with modern direct room air humidification, but also lowers the temperature and dust generation in production at the same time.
V-ZUG, Switzerland
As a manufacturing company for household appliances for kitchens and laundry rooms, V-ZUG has a dual impact on the environment: they design appliances to be as efficient in use as possible, and they produce these appliances with maximum resource efficiency and minimal emissions.
The new Zephyr Hangarœ building at the Zug site houses a new sawtooth-roof structure that includes the pressing facility, where manufactured parts are also enameled. These production processes generate large amounts of waste heat, resulting in extremely dry indoor air, which in winter can drop to just 10 percent relative humidity. This presents a major challenge for the comfort of employees and the wood-intensive building, as the wooden structure requires a minimum humidity level of 30 percent relative humidity. Additionally, this situation poses a significant challenge for sustainable cooling.
This is where Condair comes into play! The solution involves Condair˜s high-pressure nozzle system,
ML-FLEX, with 152 nozzles providing a nethumidification capacity of approximately 280 liters per hour and a simultaneous, calculated evaporative cooling effect of 16 Kelvin, meaning the room air is sustainably cooled from around 38 degree centigrade to approximately 22 degree centigrade during the humidification process.
The new Zephyr Hangarœ building at the Zug site houses a new sawtooth-roof structure that includes the pressing facility, where manufactured parts are also enameled. These production processes generate large amounts of waste heat, resulting in extremely dry indoor air, which in winter can drop to just 10 percent relative humidity. This presents a major challenge for the comfort of employees and the wood-intensive building, as the wooden structure requires a minimum humidity level of 30 percent relative humidity. Additionally, this situation poses a significant challenge for sustainable cooling.
This is where Condair comes into play! The solution involves Condair˜s high-pressure nozzle system,
ML-FLEX, with 152 nozzles providing a nethumidification capacity of approximately 280 liters per hour and a simultaneous, calculated evaporative cooling effect of 16 Kelvin, meaning the room air is sustainably cooled from around 38 degree centigrade to approximately 22 degree centigrade during the humidification process.
Sabuj Agro Tea Factory, Bangladesh
The Sabuj Agro tea factory in Bangladesh has installed a Condair JetSpray humidification system to maintain the perfect humidity in its production facility and ensure the highest quality black tea.
By maintaining 95%RH in the factory, moisture loss from the cut leaves is significantly reduced. This improves the fermentation process, resulting in a more flavoursome tea with greater market value.
By maintaining 95%RH in the factory, moisture loss from the cut leaves is significantly reduced. This improves the fermentation process, resulting in a more flavoursome tea with greater market value.
Bajrang Tea, India
JetSpray humidifiers from Condair are maintaining an optimum 95% relative humidity (%RH) above the continuous fermentation machines at Bajrang Tea factory in West Bengal, maximising the quality of the tea produced there. The improved humidity control has resulted in enhanced fermentation of the tea with better infusion and liquor, and ultimately a higher market value.
HP Graphics Experience Center, Barcelona (Spain)
In-room humidification protects against electrostatic discharge, dimensional changes in the paper and fluctuating print quality in digital printing.
Harrier Group, UK
Harrier Group, a leading UK digital printing firm, has invested in four Condair RS restive steam humidifiers to maintain the perfect production environment in its newly-designed, high-tech print room.
Parmeshwari Tea, India
Humidity control specialist, Condair, and its Indian distributor, Regent Machine & Servicing, has supplied and installed a JetSpray humidification system at Parmeshwari Tea factory in Assam. The compressed air and water spray humidifier is maintaining the ideal humidity in the CTC and CFM areas to prevent moisture loss from the tea during processing and fermentation. This results in a consistently high quality tea, which is blacker and with stronger liquor, no matter what the ambient weather conditions are like.
Tuna fish canning factory
Condair's JetSpray humidifier is helping refrigeration equipment specialists ICS Cool Energy increase profits at a leading worldwide brand of canned fish by $1 million per year. By maintaining a high humidity around the fish after steaming, evaporative weight loss from the cooked fish has been reduced from approximately 5% to 0.67%. The humidification system is preventing up to 8.5 tonnes of product from simply evaporating each day between cooking and canning.After steaming, the fish needs to be rapidly cooled in order to be processed and canned but can lose up to 20% of its moisture in the process, impacting significantly on its weight. As the factory processes up to 200 tonnes of fish each day, this severely reduced the yield on its product. ICS Cool Energy was tasked by its long standing client to find a more cost effective replacement to its existing cool room sprinkler system, which was proving inefficient in terms of energy and water usage.
Fujifilm Imaging and Innovation Centre
A Condair JetSpray humidification system is maintaining an ideal 40-60%RH (relative humidity) in the Fujifilm Imaging and Innovation Centre in Bradford to provide the optimum atmospheric conditions for their paper storage and printing areas.
Humidity control at GM Steel meat processing in Scotland
Condair’s JetSpray humidifier is helping abattoir equipment specialists, GM Steel, reduce carcass moisture loss after slaughter by up to 1.5%. By maintaining a consistently high humidity in the chill down area, GM Steel has been able to reduce the moisture loss of a carcass from around 2.5% to less than 1%.
For an abattoir processing 3,500 carcasses per week and an average cost of beef at $4/kg, this technology could increase profits by over $2M per year by preventing over 500,000kg of beef simply evaporating into its chill store’s atmosphere.
Robert Ten Cate, consultant at GM Steel, explains the process, “A carcass coming from the slaughter line is wet and warm. When it is introduced to the chill store, the cold dry air strips moisture from its exposed surface. The amount depends on the abattoir’s cooling technology but it can be anywhere between 1.2-2.5% of its total weight, and sometimes even more. By maintaining a high humidity in the chill store with a JetSpray humidifier during the initial cooling, moisture loss from the carcass is inhibited and can be reduced to less than 1%.
For an abattoir processing 3,500 carcasses per week and an average cost of beef at $4/kg, this technology could increase profits by over $2M per year by preventing over 500,000kg of beef simply evaporating into its chill store’s atmosphere.
Robert Ten Cate, consultant at GM Steel, explains the process, “A carcass coming from the slaughter line is wet and warm. When it is introduced to the chill store, the cold dry air strips moisture from its exposed surface. The amount depends on the abattoir’s cooling technology but it can be anywhere between 1.2-2.5% of its total weight, and sometimes even more. By maintaining a high humidity in the chill store with a JetSpray humidifier during the initial cooling, moisture loss from the carcass is inhibited and can be reduced to less than 1%.
Luxury Window and Door Manufacturer Uses Condair to Produce Flawless Products
Founded in 1975, Fenêtres MQ has built a reputation for creating luxury custom engineered windows and doors for the most demanding criteria. Their manufacturing facility in Ste-Agathe, Quebec, sources exceptional materials that requires a precise environment to maintain the final product quality expected by their customers.
Quotes from our customers
Gerhard Meier
CEO"In-room humidification and process water from Condair guarantee us additional process reliability and quality assurance."
Aditya Agarwal
Director“Before we had the JetSpray humidifier, we were unable to achieve the high humidity levels we needed. Our previous humidification system also tended to cause wet patches on the floor nearby. However, since we had the JetSpray humidifier installed, the area is consistently at 95%RH and we’ve managed to virtually eliminate weight loss from the tea during fermentation. This means the moisture stays in the leaf, improving the tea’s fermentation and enhancing the quality of our finished product. We’ve found the JetSpray humidifier very easy to operate and the use of compressed air in the aerosol ensures we never get any drips from the nozzles or wetting on the floor."
Mukesh Saxena
Chief General Manager of Fabric Operations"The Condair JetSpray is maintaining the ideal humidity of 60%RH in Auro Weaving’s warping section. This significantly reduces the generation of fly and yarn breakages, helping us to deliver the highest efficiency and quality in the department. Since we installed the JetSpray humidification system, the ambience of the area is very comfortable and clean. We would highly recommend the JetSpray for humidification in warping and yarn storage, where reliable and accurate humidity control is essential."
Steve Freeman
Jet Press Solutions ManagerHumidity control is important for paper handling consistency when running lighter weight stock on the Jet Press 720S in both the feeder and jetting area. We aim to maintain an RH of between 40% and 60%. Below this could potentially cause an increase in paper handling issues on light weight paper.
Once the humidifier was up and running correctly, it has performed well. It now easily and quickly gets the room up to the required RH and maintains this after start-up.
Once the humidifier was up and running correctly, it has performed well. It now easily and quickly gets the room up to the required RH and maintains this after start-up.
Robert Ten Cate
ConsultantBy maintaining a high humidity in the chill store with a JetSpray humidifier during the initial cooling, moisture loss from the carcass is inhibited and can be reduced to less than 1%.
Malcolm Edwards
Group Technical ManagerThe JetSpray has been in operation now for a number of months keeping the humidity well over the required 90%RH and maintaining a very low 0.67% weight loss. The energy and water savings are a bonus, and economies will also be achieved through its easy maintenance programme. All in all, our client could not be happier, and neither could we.
Frequently asked questions
What else influences evaporative loss?
What additional measures can be taken, alongside humidification, to mitigate evaporative losses?
Will humidification cause materials to absorb moisture?
How can the potential return on investment of a humidifier be determined?
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