Plastic Systems revolutionises dehumidification by optimising Honeycomb rotor technology – for efficiency, control, and sustainability

Plastic Systems S.r.l. takes another step forward in drying technology by optimising its Honeycomb rotor technology. The result is a solution that combines high energy efficiency, easy control, and greater sustainability. In an industry where demands for performance, traceability, and sustainable production are constantly increasing, Honeycomb technology offers several significant advantages over traditional tower and rotor dryers. It delivers lower energy consumption, high operational reliability, and a more stable drying process.

High performance and reduced energy consumption

One of the greatest advantages of Honeycomb technology is its optimised regeneration process. Regeneration takes place at significantly lower temperatures than in traditional tower dryers: around 160°C compared to 240°C. This reduces energy consumption, extends component lifespan, and lowers environmental impact.

With dew point control, the drying process automatically adapts to demand. This ensures even, stable drying while keeping energy use at an optimal level.

The continuous rotation of the rotor eliminates the transition phases found in tower dryers, providing a stable process without fluctuations. The three process circuits for heating, regeneration, and cooling are also equipped with integrated energy recovery, further improving overall system efficiency. The inverter-controlled process blower adjusts the airflow in real time to current operating conditions.

Robust design and simplified maintenance

The Honeycomb rotor used by Plastic Systems is designed for long service life and high reliability. Its new chemical formulation, combined with a compact design, provides greater resistance to thermal stress.

The rotor assembly features a chain drive with automatic self-tensioning, ensuring smooth, consistent rotation over time. The result is simpler maintenance, lower operating costs, and more stable production.

Smart control and Industry 4.0

Plastic Systems’ Honeycomb dryers are equipped with a touchscreen, PID control, and Ethernet connectivity. Thanks to support for open communication protocols such as Modbus and OPC UA, the systems can be fully integrated with MES systems and remote monitoring platforms.

With the Easy Settings function, the operator only needs to enter the material type and hourly throughput. The system then automatically calculates the correct temperature, airflow, and anti-stress settings, simplifying operation and reducing the risk of operator error.

Compact drying solutions for lower material throughput

For applications with lower material consumption, Plastic Systems has developed the DWH series. The units are compatible with drying hoppers up to 200 litres and can be mounted directly on the machine feed throat, eliminating the need for floor space.

The DWH series features a new design that further improves both performance and usability. Compact process circuits and integrated heating chambers deliver high thermal efficiency and low energy consumption.

The result is an energy-efficient drying solution with performance comparable to the standalone dryers in the DW series.

Total flexibility with multi-hopper systems

For production environments where several materials are handled simultaneously, Plastic Systems offers multi-hopper systems based on the DW series. Each drying hopper is controlled individually with its own process parameters, providing maximum flexibility and process control.

Each hopper is equipped with:

• Dedicated heater
• Local control panel with temperature and material display
• Automatic valves for airflow regulation
• Automatic anti-stress protection and centralised filter

This solution makes it possible to process different materials simultaneously, each with individually optimised process steps. It also reduces changeover times for material and product changes, contributing to higher productivity.

Patented technology for maximum efficiency

Plastic Systems’ DWC system, protected by a European patent, uses load cells positioned beneath the drying hopper to continuously measure the amount of material processed in real time.

This enables:

• Precise calculation of drying time
• Full traceability and recording of actual material consumption
• Automatic adaptation to different materials

The operator only needs to select the material type. The system then automatically manages the drying process and optimises operation based on current conditions.

An additional benefit is that the dryer’s process blower can also be used to convey material to both the dryer and the processing machine, contributing to a more compact and energy-efficient installation.