The Challenge:

An inaccurate dew point can lead to various problems that impact both production efficiency and product quality. The dew point is the temperature at which air reaches 100% relative humidity, causing water vapor to condense into liquid. When the dew point is not properly managed, several issues may arise:

Condensation on Equipment: A high dew point can cause moisture to accumulate on machinery, equipment, or surfaces. This can lead to rust, corrosion, and electrical malfunctions, potentially causing equipment failures or production downtime.
Product Quality Concerns: In industries like food or pharmaceuticals, controlling both temperature and humidity is essential to maintaining product quality. An improper dew point can result in products being too wet or too dry, which can negatively affect their shelf life, appearance, and functionality.
Steam Explosions in Metalworks: Introducing moisture into molten metal can cause dangerous steam explosions, posing serious risks to both equipment and personnel.
Uncomfortable Working Conditions: A mismanaged dew point can create a high-humidity environment, leading to employee discomfort, lower productivity, and possible health issues, particularly in warm climates.
Energy Inefficiency: An improper dew point can reduce the efficiency of air conditioning and ventilation systems. Without proper humidity control, cooling units or humidifiers have to work harder to maintain the desired temperature and humidity levels, increasing energy consumption.
Microbial Growth: A low dew point (very dry air) can lead to static electricity, while a high dew point fosters the growth of mold, bacteria, or fungi, which can damage both products and employee health.

Solution:

By using our Neuron Humidity Sensor together with the Neuron Virtual Sensor, both temperature and relative humidity can be monitored to calculate the dew point temperature with the following formula:

R = Relative humidity (%)
T = Air temperature (°C)

Dew point temperature (for R > 50%*) in °C: T - (100 - R) / 5

M = Material temperature (°C)

Deviation from material to dew point temperature: M - (T - (100 - R) / 5)

Monitoring the dew point provides several significant benefits, especially in processes where humidity, temperature control, or energy management is critical. Some key advantages include:

Preventing condensation: Monitoring and managing the dew point helps avoid condensation on machinery, pipes, or surfaces. This prevents issues like corrosion, mold growth, or electrical faults, which can damage equipment and halt production.

Optimizing humidity levels: In industrial operations like food manufacturing, pharmaceuticals, or chemical processing, controlling humidity is crucial. By monitoring the dew point, you can adjust the environment to maintain consistent production quality and stability.

Improved energy efficiency: Managing the dew point contributes to more efficient use of energy in processes like air conditioning and drying. Reducing unnecessary moisture and excessive heat lowers energy consumption and operating costs.

Increased safety in metalworks: Continuous dew point monitoring ensures that moisture doesn't interfere with alloys in molten metal processes, thus preventing dangerous steam explosions.

Protecting products from damage: In processes requiring strict temperature control—such as cooling or storage—a high dew point can lead to excess moisture, which can damage products. Controlling the dew point ensures product integrity and quality.

Better process control and product quality: For systems like dryers, compressors, and refrigeration units, precise dew point control ensures better process stability and consistent product quality.

Preventing corrosion and rust: High humidity levels can cause condensation, leading to rust and corrosion. By controlling the dew point, the risk of these issues is minimized, which helps extend the life of machinery and equipment.

Enhanced safety: In environments like chemical or pharmaceutical production, excessive humidity or condensation could trigger hazardous reactions or degrade chemicals. Proper dew point management reduces these risks.

Controlling the dew point ultimately leads to greater operational reliability, higher product quality, reduced maintenance, lower energy costs, and a safer working environment.