RESIN DRYING

Resin dryers can last a long time. There is no “typical” lifespan of a dryer.  Some processors might replace the equipment every three to four years as part of a capital equipment replacement plan.  This will ensure that they have the latest technology.  Other processors will keep their equipment for decades.

Keeping a resin dryer too long may not be a good value. You might not want to invest in a cost of a new dryer – but you’re not always saving money that way, because you’re likely paying more for maintenance and energy usage on your existing, less-efficient technology.

If you have older dryer technology, it’s wise to invest in state-of-the-art equipment because it's going to save you money in the long run – and it's going to make your product more consistent with less waste. Less waste means more profitable production. Current built-in material protection systems reduce scrap even more.
 

While payback analysis on different models will vary greatly, as a general guideline you can expect up to 40% energy savings depending on the dryer you currently have and the newer  dryer technology you purchase.

If you delay your decision to purchase a new dryer, you may be missing out on the increased ROI that newer technology can offer.  In the year you spent without that new dryer, it could have paid for itself in operational savings.

Consider these scenarios in which purchasing a new resin dryer is the best solution:

Your dryers are breaking down – a lot: If your dryers are spending more time with your maintenance team than on the production line, they might be telling you it’s time to invest in new technology.

You replace a broken dryer with one from inventory: If a resin dryer reaches its end of life and you’re thinking about replacing it with one from your inventory that’s just as old, think again. Old resin dryers aren’t as efficient as current, advanced technology. New dryers ensure accurate and uniform temperatures, control air flow to heat every pellet, employ precise dew point and reduce drying times. New technology means faster changeovers and startups.

Bad parts piling up: If you notice more rejected parts than usual are populating your work cells, your resin dryer might be the culprit. Perhaps the unit isn’t properly connected to the rest of your process monitoring system, and material is being overdried or underdried. Newer dryers possess powerful features like temperature setback, automatic air flow adjustment and constant monitoring and adjustment of all dryer operating conditions to maximize energy savings and optimize material processing. Other current dryer features that help prevent bad parts include material selection tables with pre-set or programmable drying parameters; visual and audible alarms; and material protection management, which monitors the loading system to prevent material overdrying and degradation. Optional Industry 4.0 systems can capture detailed operational parameters  at key points in the drying process.

Utility costs are skyrocketing: Electric bills don’t tend to go down and utility costs are rising noticeably. New dryers are engineered to be more energy efficient – so much so that a large molder might save thousands of dollars in electric costs in one year by upgrading just one dryer. With governments and utilities offering rebates for energy sustainability, that’s further incentive to purchase dryers that use less energy.

In conclusion

Upgrading your resin dryers isn’t just about keeping up with technology – it’s about keeping your operation efficient, cost-effective and competitive. Investing in modern drying systems pays dividends in energy savings, production consistency and long-term reliability.