For many printers, investing in a completely new dryer may not be the most necessary or cost-effective option. That’s where Contiweb’s smart enhancements come in. These practical solutions improve efficiency, extend the useful lifespan of older equipment, and can make a real difference in your operations. Additionally, many countries offer government subsidies for investments in energy-efficient equipment, making these enhancements even more financially attractive.
In this blog post, we’ll explore the most popular enhancements for hot air dryers that can help improve your business’s efficiency, sustainability, and profitability.
1. Single Burner Operation Enhancement
Contiweb dryers are engineered for high-performance drying, capable of managing the full web width at very high speeds. However, not every print job requires such maximum output—especially when dealing with lower ink coverage or reduced production speeds.
With the Single Burner Operation enhancement, the upper burner chamber can be deactivated. When deactivated, hot air from the lower burner chamber is efficiently. This ensures effective drying on both sides of the paper while maintaining the high-quality results you expect.
In these situations, the Single Burner Operation enhancement enables the dryer to generate less drying heat, providing a cost-effective, energy-saving solution. It also reduces fossil energy consumption, helping to minimize your carbon footprint while maintaining operational efficiency.
The dryer can be easily switched from normal operation to Single Burner Operation using the HMI panel, giving operators full control and flexibility over the drying process.
2. Burner Chamber Replacement
The burner chambers are the heart of a Contiweb dryer, responsible for combusting ink solvents at very high temperatures (around 800°C), which results in clean air emissions that meet legal exhaust requirements. By using efficient heat exchangers and maintaining low airflows, Contiweb ensures gas consumption remains minimal.
As the burner chambers age, repairs become more frequent, costs rise, CO emissions may exceed legal limits, and airflow can be compromised. The most costly risk is unplanned burner downtime, which can halt production.
The Contiweb Burner Chamber Replacement Enhancement addresses these issues by replacing worn burner chambers with upgraded versions. This restores optimal combustion, improves energy efficiency, and reduces fuel costs without the need for a full dryer replacement.
This enhancement involves replacing the old burner chambers with upgraded versions, ensuring optimal combustion and more efficient heat generation. By replacing worn-out burner chambers, printers can restore peak efficiency, reduce energy consumption, and lower fuel costs while extending the operational life of their existing equipment.
3. Gas Reduction Enhancement (GRE)
With the increasing demand for cost efficiency and the growing pressure to reduce environmental impact, the Gas Reduction Enhancement (GRE) offers a powerful solution for printers looking to optimize their dryer’s fuel consumption. The GRE includes two relatively simple but highly effective options—Standby GRE and Production GRE—that can lead to significant gas savings by optimizing solvent concentration in the burner chambers.
The Standby GRE enhances control to minimize gas consumption when the dryer is in standby mode, ensuring that fuel isn’t wasted when the system isn’t actively drying. The Production GRE, on the other hand, reduces gas usage during production by improving the combustion process. Together, these enhancements help lower operational costs and improve energy efficiency.
The solvent control method used in the Gas Reduction Enhancement is the same technology that powers our latest Ecoset dryers, already recognized as the most efficient hot air dryer in the heat-set web offset industry. Contiweb has now made this advanced technology available as an enhancement for older Contiweb and Vits dryers, enabling you to significantly reduce gas consumption without the need for a complete equipment overhaul.
4. Electrical Power Reduction Enhancement
Reducing electricity consumption has become a top priority for printing companies looking to optimize their operations. Contiweb's Electrical Power Reduction Enhancement offers a practical solution to help printers minimize power usage of their dryer while maintaining output quality and efficiency.
The enhancement works by optimizing the drive system and adjusting the drive speeds to reduce electricity consumption during the drying process. By optimizing the electrical power required to drive the fan motors and other components, the system operates more efficiently, consuming less energy while still delivering high-quality drying performance. This results in reduced operational costs and lower energy consumption, making it a valuable upgrade for older dryers.
The Electrical Power Reduction Enhancement can be implemented on older Contiweb and Vits dryers, making it an easy and cost-effective way to enhance energy efficiency. With this upgrade, printing companies can immediately lower electricity usage, resulting in significant cost savings while supporting sustainability efforts and reducing carbon emissions.
Making the right decision
Contiweb’s dryer enhancements offer an effective and cost-efficient way to improve your dryer’s performance and efficiency without the need for a complete dryer replacement. These upgrades can save you money, reduce energy consumption, and support your sustainability goals—while offering long-term reliability.
Additionally, government subsidies are available in many countries to help offset the initial cost of these energy-efficient upgrades, making these enhancements even more financially appealing.
At Contiweb, we are committed to helping you make the best decisions for your business’s future. By leveraging remote monitoring of your dryer’s performance, we can provide you with tailored, data-driven advice to ensure you select the optimal enhancements for your operational and sustainability targets. Let us guide you through the available options to maximize your dryer’s potential.
