Right-sizing dehumidification for manufacturer of processed glass

The challenge: Finding the Goldilocks solution

ESG is one of the UK’s leading glass processors, producing one of the largest and most technologically advanced ranges of processed glass for commercial buildings, balustrades and more. The manufacturing process involves laminating glass with plastic layers, which requires strict climate control.

The lamination process therefore takes place in a temperature and humidity-controlled room, where relative humidity must be maintained at an extremely low level of 20–30%.

When ESG's existing dehumidifier, with a capacity of 6,000 m³/hour, was nearing end of its life, the company sought a more energy-efficient replacement. The unit, serviced by Dantherm Group, was consuming more energy than modern technology would require.

During the formal bidding process, responses varied considerably: one supplier proposed a unit that appeared undersized for the application, while others recommended like-for-like replacements at 6,000 m³/hour capacity, matching the existing unit's specifications. This was not the tailored approach ESG required.

ESG ultimately selected Dantherm Group's proposal, based on the detailed calculations and technical explanations provided during the bid process.

Solution: Analysis and specification

Dantherm Group conducted a calculation based on ESG's process parameters and environmental conditions. This included assessment of the production area volume, airflow patterns, ambient conditions and moisture load.

The analysis determined that a smaller unit would meet ESG's humidity requirements while reducing energy consumption. The recommended model was the TTR 3700 desiccant dehumidifier, with a nominal air flow of 3,700 m³/h and a dehumidification capacity @ 20°C/60% RH of 20.5 kg/h.

Energy savings were calculated on two major factors:

Regeneration wheel: The largest energy demand in a desiccant dehumidifier. The wheel continuously removes moisture from the desiccant material, accounting for the majority of operating costs.

Air movement: The fan operates continuously during production, creating a baseline energy consumption.

On this basis, energy savings were estimated at approximately 30%.

“With the replacement of the outdated dehumidifier with a new and efficient one, we wanted to optimise our electricity efficiency. Dantherm was the most responsive of the bidders, providing informative feedback on all questions. They invested time in calculating the solution, which will ultimately save us considerable costs without compromising performance.”

Scott Sinden, Managing Director, ESG

Results: Energy savings and operational efficiency

• The TTR 3700 maintains a stable relative humidity of 20–30%, essential for ESG’s product quality.
• Energy consumption has decreased by approximately 30% compared with the previous unit, reflecting the lower capacity requirements identified during the analysis phase.
• The properly sized capacity avoids the inefficiencies of oversized units, which cycle on and off frequently, and the continuous maximum-load operation typical of undersized units.

Key takeaways

This project demonstrates the value of process-specific capacity calculations in dehumidification system specification. Rather than replacing existing capacity on a like-for-like basis, a detailed analysis of actual requirements identified an opportunity to reduce operating costs while maintaining required performance levels.

Key factors in the project outcome included:

• Thorough assessment of process parameters and transparent communication of calculation methodology.
• Dantherm Group’s broad range of desiccant/adsorption dehumidifiers, enabling the best match for the customer’s needs.
  

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