Dryer
3 Common Mistakes That Reduce Dryer Lifespan Often Overlooked by Technicians
An industrial dryer often operates for tens of hours daily, yet are you aware that even minor mistakes can significantly impact the operational process? Some workshops have to replace heating elements in less than a year, while others, using the exact same model, enjoy durability lasting 5–7 years. The difference lies in the usage and maintenance practices.
This article will focus on pointing out three common mistakes that reduce the lifespan of dryers, which technicians often overlook during operation.
Placing the Dryer in Restricted, Humid Areas, or Against the Airflow Direction
The majority of industrial dryers have systems for continuous suction and discharge of hot air. When the machine is placed in an area with restricted airflow, or where hot air is blown back into the unit, the heat exchange process is severely hampered. Heat accumulates within the drying chamber, the fan motor has to run longer, the motor quickly overheats, sensors give inaccurate readings, and the circuit boards continuously bear a high load.
This explains why the same machine model can last 5–7 years in one location but requires replacement of heating elements or circuit boards after only 2 years in another.
The simple solution is to leave a clear space of at least 50 cm behind the machine, avoiding placement close to walls, humid areas, or near steam sources. If the workshop has many other heat-generating devices, the dryer should be positioned according to natural airflow direction or with support from ventilation fans.
Incorrect or Insufficient Routine Cleaning and Maintenance
Naturally, routine cleaning and maintenance are essential and unavoidable. Many technicians clean the dryer by merely wiping dust off the exterior casing or cleaning the air filter. However, the drying compartment, fan blades, and hot air ducts are where residue, oil vapor, or fabric lint accumulate most easily. These substances not only reduce the speed of the airflow but also increase the risk of fire or explosion when the temperature rises.
Proper maintenance includes 3 basic steps:
- Cleaning the air filter after every work shift.
- Checking the fan and heat ducts weekly, ensuring they are not clogged or coated with oil.
- Every 3–6 months, removing the exterior casing to vacuum dust from the motor, heating elements, and control board.
If the workshop uses chamber-type dryers, such as the Trotec DH-series models (common in electronics production, printing facilities), which are designed for easy disassembly during cleaning, technicians can reduce maintenance time and double the lifespan of components like temperature sensors and air circulation fans compared to machines running continuously without maintenance.
Neglecting to Check Actual Output Humidity and Temperature
A dryer reaching the set temperature does not necessarily mean the material has achieved the required dryness level. Many workshops rely solely on the display gauge and fail to use a thermometer or hygrometer to measure the actual output. When the temperature deviates, the sensor operates inaccurately, and the drying system continuously attempts to compensate for the heat loss, leading to the heating element becoming overloaded.
For temperature-sensitive materials such as electronic components, printing paper, powder coatings, or engineered plastics, a mere difference of 3–5°C is enough to alter product quality.
The solution is to periodically verify the output temperature using specialized measuring devices, while simultaneously recording the difference between the set and actual temperature. This helps in early detection of sensor errors or faults within the PID controller.
Refer to the two dryer lines supplied by EMIN:
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