At 20°C on the thermostat and 70% RH in the warehouse, losses are already occurring. Cardboard loses its structural rigidity, and electrical equipment begins to corrode at its contacts and sensors. The air-conditioning system consumes 10–30 per cent more energy to achieve the same thermal result.
The goods arrive at their destination with damaged packaging, leading to rejection on delivery, contractual penalties and return costs. Measurements carried out by Texco during 48-hour audits confirm that none of these consequences appear in the alarm log, but rather in the balance sheet, in complaints and in discussions with customers. Below, we have documented five operational bottlenecks caused by a single parameter that has got out of control, along with the technical solutions that address them.
Bottleneck 1: Stacking resistance
The problem: A warehouse manager notices that the stacks in the receiving area are starting to lean two or three days after new pallets have been received. The goods at the bottom are deteriorating before delivery. The team reports that the packaging is limp and no longer has the rigidity it had when it entered the warehouse. The immediate conclusion: poor-quality cardboard. The correct conclusion: high humidity in the warehouse.
Cardboard is hygroscopic. Moisture absorption leads to the phenomenon of creep (progressive deformation under a constant load), which explains why the stacks give way over time, rather than instantly. At relative humidity levels above 60% RH, it absorbs water vapour and can lose up to 30–40% of its vertical compressive strength, depending on the type of material. The process is gradual, taking place over several days, and produces no visible signs until the stack collapses. In warehouses storing goods packed in cardboard, uncontrolled humidity is the main cause of product deterioration before goods are removed from stock.
Critical threshold: above 60% RH, the stacking strength of cardboard decreases progressively. At 80% RH, structural damage becomes significant within 24–48 hours.
✅ Integrated solution: Condair DC condensation dehumidifiers maintain humidity below 60% RH in large-volume warehouses with moderate temperatures, between 15 and 35°C. For cold stores or spaces with temperatures below 15°C, where condensation becomes ineffective, the Condair DA adsorption dehumidifier takes control of the parameter independently of the ambient temperature. Texco sizes the system according to the hall’s volume and the humidity profile measured throughout the year.
- Condair DC (condensation): optimum efficiency in warehouses with temperatures between 15°C and 35°C.
- Condair DA (adsorption): the solution required for spaces below 15°C or for strict humidity control, regardless of temperature.
Problem 2: Corrosion of equipment and automation systems
The problem: The maintenance manager at a logistics centre has noticed that the forklift trucks are experiencing an increased rate of sensor faults. The electrical contacts on the conveyors need replacing more frequently than the standard schedule stipulates. The electronic components of the automation systems are being replaced at shorter intervals than those covered by the warranty. Each incident is dealt with separately, attributed to normal wear and tear or a faulty batch of parts. The underlying cause remains undiagnosed.
Air with high relative humidity accelerates the oxidation of metal surfaces and electrical contacts. At 70% RH and a temperature of 20°C, the corrosion rate of iron can increase significantly (even several-fold), depending on the conditions. Control electronics, sensors and relay contacts are the most sensitive components.
Safe range: 40–55% RH for areas containing electrical and electronic equipment.
✅ Integrated solution: Controlling humidity in logistics facilities by maintaining it between 40–55% RH in areas containing electrical and electronic equipment eliminates the main factor that accelerates oxidation. Condair DA is the ideal solution for warehouses where temperatures vary significantly between day and night or between seasons, as it operates independently of air temperature.
Challenge 3: Energy consumption of the air-conditioning system
The problem: The operations manager analyses the energy bills for the last 12 months and notices that months with high temperatures do not always coincide with peaks in consumption. During the summer months, when atmospheric humidity is high, consumption exceeds estimates based solely on the outdoor temperature. The difference is not attributed to any specific cause. It is classified as a seasonal variation.
Air saturated with water vapour has a higher specific heat capacity than dry air. An HVAC system that brings outdoor air to the desired temperature under conditions of high humidity may consume 10 to 30 per cent more energy, depending on the conditions.
Measurable example: a 5,000 m³ warehouse with a 100 kW HVAC system operating at 75% RH instead of 50% RH may consume an additional 15–25 kWh per hour during peak periods.
✅ The integrated solution: A dehumidifier integrated into the air-conditioning circuit reduces the thermal load on the HVAC system and lowers overall energy consumption. Condair DC, installed in parallel with the existing system, removes excess humidity before it loads the heating circuit. Texco assesses the existing configuration and identifies the integration point with the greatest impact on energy consumption.
Challenge 4: Warehouse team productivity
The problem: The warehouse manager cannot explain why picking productivity consistently drops in July and August, even though the temperature in the warehouse is maintained below 25°C. Picking errors increase by 15–20% compared with the spring months. Staff work more slowly, take more breaks and are more tired at the end of their shift.
Thermal discomfort does not depend solely on temperature. The thermal comfort index takes into account both temperature and relative humidity. At 24 °C and 70% RH, the perceived temperature is equivalent to approximately 29°C at 50% RH.
Reference parameter: the range of 45–60% RH at 20–25 degrees Celsius is the optimal thermal comfort zone, according to ISO 7730.✅ Integrated solution: Maintaining humidity between 45 and 60 per cent RH in the active work area is the key factor. The Condair ML or MLP for compact spaces, or the Condair TurboFog for large halls, ensures uniform distribution of this parameter throughout the entire operational area.
Challenge 5: Refusal on delivery and contractual risk
The problem: The customer relations manager receives a complaint from a retailer that a batch of products has been refused on delivery. The reason given is that the packaging shows signs of condensation and corrugated cardboard. The product inside is intact, and temperature conditions were maintained throughout the supply chain. However, the refusal is upheld.
In a supply chain with GDP or HACCP requirements, packaging damaged by moisture constitutes a non-conformity and may lead to the batch being rejected or to the application of contractual clauses.
Risk threshold: condensation on the packaging occurs when the temperature difference between the product and the air in the warehouse exceeds the dew point of the ambient air. At 20°C and 75% RH, the dew point is approximately 15°C.
✅ Integrated solution: Humidity control in the storage and order-picking areas eliminates the condition that causes packaging degradation prior to delivery. For warehouses with GDP or HACCP requirements, the Condair DA ensures traceability of parameters through integration with existing monitoring systems. Texco provides the technical documentation required for compliance audits.
What should you consider before making any decision?
Before selecting a system, the parameters you need to know are:
- Humidity profile throughout the year: minimum and maximum recorded values, times and seasons with critical humidity levels, correlated with ambient temperature.
- The volume of the warehouse and the type of construction: metal or concrete, with or without thermal insulation, with or without natural lighting via skylights.
- The type of goods stored and their sensitivity thresholds: cardboard, textiles, metal products, foodstuffs.
- Identified sources of humidity: leaks through the roof or walls, uncontrolled ventilation, damp goods on arrival, human activity.
- Applicable compliance requirements: GDP for pharmaceutical distribution, HACCP for food warehouses, ISO 9001 for quality management systems.
Texco carries out a 48-hour audit with real-time monitoring of humidity fluctuations at critical points within the warehouse. Sensors are positioned at different heights and in areas with varying conditions: the reception area, the storage area, the picking area and the dispatch area. Based on the measured data, the solution is tailored and the installation plan is drawn up whilst the warehouse remains in operation.
Uncontrolled humidity in a warehouse is an operational risk with five facets, each with its own cost. The Texco team identifies the source, measures the actual parameters and recommends the solution best suited to the type of goods and compliance requirements.
Contact us on +40736369802 or at office@texco.ro for a preliminary audit that will help you quickly identify the sources of losses in your warehouse.