Plastic Systems revolutionizes dehumidification by optimizing Honeycomb rotor technology: Efficiency, control, and sustainability
in an industrial landscape increasingly focused on high performance, traceability, and sustainability, Plastic Systems S.r.l. – a long-established company of the Pegaso Industries S.p.A. group – introduces significant innovations in honeycomb rotor dehumidification technology.
These solutions represent a substantial evolution compared to traditional tower and rotor systems, offering significant advantages in terms of energy efficiency and ease of management.
High performance and reduced energy consumption
One of the key features of rotor dehumidification technology is the optimization of the regeneration process, which occurs at lower temperatures compared to tower dryers (160°C versus 240°C), resulting in significant energy saving, longer component lifespan, and reduced environmental impact. The use of dew point control further reduces energy consumption by maintaining dehumidification at a constant and desired level.
The continuous rotation of the rotor eliminates transition phases between towers, ensuring a continuous, stable, and precise process. The three process circuits – heating, regeneration, and cooling – are equipped with integrated energy recovery units, further enhancing overall efficiency. The process blower with inverter allows dynamic adjustment of the airflow, adapting in real time to operating conditions.
Robust structure, simplified maintenance
The new Honeycomb dehumidifier used by Plastic Systems is designed for maximum durability and reliability: a new chemical formulation and a compact structure make it more resistant to thermal stress.
The rotor assembly includes a chain drive with self-tensioning, ensuring constant and uniform rotation. All of this helps simplify maintenance, reduce operating costs, and improve production continuity.
Smart control and Industry 4.0
Plastic Systems’ rotor dehumidifiers are equipped with touchscreen interfaces, PID controls, and Ethernet connectivity. Thanks to support for open protocols such as Modbus and OPC-UA, they are fully integrable with MES systems and remote supervision platforms.
The “Easy Settings” function allows the operator to set only the essential parameters (hourly throughput and material type), while the system automatically calculates temperature, airflow, and anti-stress configuration, minimizing the risk of human error.
Compact solutions for small-scale production
Plastic Systems has developed the DWH mini and DWH units for low hourly throughput applications. Compatible with hoppers up to 200 litres, they can be installed directly on the production feed throat, optimizing operational footprint.
Thanks to compact process circuits with integrated heating chambers, these units ensure high thermal efficiency and low energy consumption, offering performance comparable to standalone dryers from the DW series.
Total flexibility with multi-hopper systems
To meet the needs of complex production processes, Plastic Systems offers multi-hopper systems based on DW dryers, with independent parameter control for each unit. Each hopper is equipped with:
• Dedicated heating chamber,
• Local control panel with temperature and material indication,
• Automatic valves for airflow regulation,
• Automatic anti-stress system and centralized filter.
This configuration allows for the simultaneous processing of different materials, optimizing process parameters and reducing production changeover times.
Patented technology for maximum efficiency
The DWC/DWHC system, protected by a European patent, integrates high-precision load cells beneath the hopper, enabling real-time measurement of the amount of material processed. This allows for:
• Precise calculation of the dehumidification time,
• Traceability and recording of actual material consumption,
• Automatic adaptation to different materials.
The operator only needs to select the material, while the system autonomously manages the process. Additionally, the dehumidifier’s blower can supply both the unit itself and the processing machine.
A partner for sustainable transition
With over 5,000 systems installed worldwide, 10 production facilities, and more than 30 service canters, Plastic Systems is a leading technology partner in the packaging, automotive, medical, electronics, blow moulding, injection moulding, and extrusion sectors.
Honeycomb rotor technology offers a concrete response to the challenges of the ecological transition in the plastics industry, promoting more sustainable, traceable, and optimized production.
