Excessive humidity in the supply air reduces the vapour pressure gradient between the product and the air. The consequences are reduced evaporation rates, longer drying times and higher energy consumption. At the same time, high exhaust air humidity can be an indication of inefficient drying, for example due to condensation, inadequate air routing or overloading of the system. In such cases, undesirable material deposits often occur.
Excessively low humidity in the exhaust air should be viewed critically. It often indicates overdrying. This leads to unnecessary energy consumption and can also impair product quality. Loss of flavour, powder breakage and increased dust formation are typical consequences.
Humidity measurement – an elementary step in the process
Absolute humidity is a key control parameter. It has a decisive influence on how much moisture the air can absorb and therefore how effectively evaporation takes place. Without reliable measurement of this parameter, it is difficult to control the desired degree of drying and process control, and fluctuations in the ambient or process air remain undetected. This leads to inconsistent product quality, higher reject rates, inefficient use of energy and potential caking or safety risks.
This is exactly where the CO.Pilot from REMBE comes in. The system measures the absolute humidity of the supply air and exhaust air, in real time and without the need for complex maintenance. This makes the actual drying conditions completely visible. This data can be used to control processes in a targeted manner, use energy more efficiently and stabilize production processes in the long term. The CO.Pilot demonstrably recognizes changes in humidity in the range of seconds and provides continuous measurement data. This allows the operator to adjust the process directly, e.g. by modifying the drying parameters.
The benefits at a glance
- Energy savings
- more stable drying profiles,
- improved reproducibility,
- Reduction of product deposits,
- Carbon monoxide monitoring for detecting smouldering embers, embers and fires
This enables the operator to react specifically to fluctuations in the humidity of the supply air, for example in the event of changing outdoor conditions, thus preventing under- or over-drying. This exhaust air data helps to evaluate the actual evaporation performance. The moisture measurement is carried out using a process sample, which is provided to the CO.Pilot analyser by means of a high vacuum. The moisture and carbon monoxide content is measured based on laser absorption spectroscopy.
This provides the operator with a continuous visualization of the moisture values and allows them to be linked to production data in real time. This makes the drying process traceable, controllable and optimizable in the long term.
Efficiency through transparency and control
- Energy savings through real-time control of the air conditions in the drying process
- Early recognition of deviations
- Consistent product quality under changing environmental conditions
- Less cleaning effort due to reduced deposits
- CO₂ reduction and measurable progress towards sustainable process management
The CO.Pilot makes the invisible visible:
With laser-based humidity measurement and CO detection, it enables optimized, safe and sustainable spray drying. It creates transparency in the process, saves energy, stabilizes quality and reduces the risk of incidents – a smart tool for modern drying technology.
The combination of humidity measurement and CO detection for early fire detection in a single, robust system. The CO.Pilot covers two critical process aspects: Efficiency and safety.
POWTECH TECHNOPHARM 2025 – Visit REMBE in hall 9 at booth 9-503From September 23 to 25, the international processing community will meet again in Nuremberg. You can look forward to exciting live explosion demonstrations, new product highlights as well as fresh impulses and individual solutions from our experts
