In the management of a production facility, technical parameters are often monitored strictly in terms of machinery performance. However, an imbalance in the microclimate – particularly relative humidity – can become a constant source of hidden costs. Relative humidity affects costs through scrap and maintenance, so maintaining precise control over the working environment is a direct way of protecting existing investments in expensive equipment.
For an experienced manager, humidity is not merely a technical detail, but a critical business factor, as uncontrolled fluctuations can lead to losses of 5–15 per cent of production due to scrap.
Texco’s expertise in microclimate control
At Texco, we approach humidity from a perspective of in-depth diagnosis, not merely by supplying equipment. Our approach is based on:
- Experience in identifying imbalances: We analyse the specific causes leading to microclimate instability in complex industrial spaces.
- Optimisation of existing processes.
- Reducing operational risks: We understand the pressure to meet delivery deadlines and the need to avoid contractual penalties caused by non-compliant quality.
- Documented technical support: We provide concrete data and the necessary certifications for regulated industries, through technical support aimed at reducing risks.
This approach enables us to transform an unpredictable working environment into a stable system, where quality is a priority and maintenance becomes predictable.
What is relative humidity?
To manage an industrial hall effectively, it is important to understand that air behaves like an invisible reservoir of moisture, whose storage capacity changes with temperature. Relative humidity (RH) is the ratio between the amount of water vapour present in the air at any given moment and the maximum amount that the air can hold at that specific temperature.
A common mistake in industrial settings is to ignore the fact that warm air can hold much more water than cold air.
When the temperature in a hall drops without the absolute humidity being controlled, the relative humidity automatically increases, even if no additional water has been added to the system.
- Warm air: Its molecules are more widely spaced, allowing a greater quantity of water vapour to remain in suspension
- Cold air: Has a lower holding capacity; if it is cooled below a certain threshold (the dew point), the excess water turns into condensation.
Relative humidity is not just a figure on a sensor, but an indicator of process stability.
- Impact on materials. Many raw materials (wood, paper, textiles or metal powders) are hygroscopic, meaning they absorb or release water depending on the relative humidity (RH) of the ambient environment.
- Process accuracy. Fluctuations in humidity can alter the dimensions of materials or their chemical properties, leading to production errors and scrap rates that can reach the 5–15 per cent threshold mentioned in efficiency analyses.
- Asset protection. Maintaining an optimal RH helps prevent corrosion on machinery in which significant sums have been invested (often between 200,000 and 500,000 euros), thereby extending its service life.
Why is humidity important in industrial halls?
Managing relative humidity protects equipment, products and staff in industrial halls. Controlling this parameter reduces operational risks in factories with a turnover of €2–10 million.
Impact on equipment
Investments in expensive machinery are at risk of deterioration if RH exceeds 50–60 per cent.
- Corrosion: High RH accelerates the oxidation of metal components and leads to faults and costly repairs.
- Condensation: Temperature drops below the dew point cause condensation to form on cold surfaces, which can lead to short circuits or sensor faults.
- Maintenance: A lack of monitoring increases downtime due to unplanned repairs, rather than predictive maintenance.
Impact on products
The quality of the finished product depends on RH during processing and storage.
- Scrap: RH imbalances can result in losses of 5–15 per cent in industries using hygroscopic materials (e.g. paper, powders).
- Deformation and mould: Hygroscopic materials absorb water above 60% RH, causing dimensional changes or promoting mould growth, which affects compliance with standards.
- Reputation: Non-compliant deliveries reduce the chances of securing future contracts with major clients.
Impact on staff
The microclimate affects team performance; the optimum RH is 40–60 per cent.
- Productivity: Air that is too dry (<30% RH) or too humid (>60%) reduces concentration and output.
- Health: Extreme conditions favour pathogens, increasing absenteeism.
- Staff turnover: Poor conditions contribute to turnover rates of 20–30 per cent, generating recruitment costs (€10,500–18,000 per unskilled worker).
At Texco, we identify risks and implement technical solutions that comply with industry standards, minimising operational disruption.
Practical scenarios, real-world problems and tailored solutions
Texco identifies microclimate imbalances and proposes solutions tailored to the materials being processed and to industry standards.
- Scenario A: Static electricity in printing works
Problem: Below 40–50% RH, paper or plastic films accumulate electrostatic charges, causing sheets to stick together, feed jams and electrical arcing, resulting in production downtime.
Solution: The Condair MLP system (adiabatic humidification via fine atomisation). It increases RH to dissipate charges and stabilises the temperature, thereby reducing equipment failure.
- Scenario B: Hygiene in the food and pharmaceutical industries
The problem: Regulated industries require constant RH (typical tolerance of ±5%) to prevent the degradation of sensitive substances.
Solution: JUMAG EDI series electric steam generators, which supply high-quality, dry and controlled steam, helping to maintain relative humidity within the required range and meeting the requirements for food or pharmaceutical applications
- Scenario C: Condensation and corrosion in metal storage facilities
The problem: RH above 60% causes condensation on metals (corrosion) and weakens stored cardboard, which can lead to scrap or damage to stock.
Solution: Condair DA adsorption dehumidifier. It efficiently removes moisture at low temperatures (below 10°C), where refrigeration dehumidifiers are less effective.
- Scenario D: Wood and textile processing
The problem: Below 45% RH, wood and textiles crack or lose weight; above 65% RH, they absorb excessive moisture, which affects their dimensions and quality.
Solution: Industrial adiabatic humidification systems (e.g. Condair MLP), integrated with humidity sensors and automatic control, distribute fine mist throughout large halls, stabilising RH quickly and efficiently and protecting the materials being processed.
Common problems caused by incorrect humidity
A checklist for production managers includes:
- Condensation on metal surfaces, indicating a risk of corrosion to machinery.
- Mould or packaging degradation. This occurs at RH levels above 60–70 per cent, exceeding storage standards.
- Static electricity. Occurs at RH below 40–50 per cent, causing jams in packaging or printing.
- Consistent scrap rates (5–15 per cent). Indicates RH fluctuations affecting hygroscopic raw materials.
Humidity measurement and monitoring
For total control over processes, monitoring cannot be left to chance.
- Industrial sensors: Unlike commercial solutions, industrial sensors provide the precision required for regulated industries, where stability is a priority.
- HVAC integration: Linking monitoring to automated ventilation systems enables an immediate response to changes in the microclimate, ensuring compliance with strict production standards
Humidity control solutions
The choice between different technologies depends on the technical specifications of each hall and the energy efficiency objectives.
Humidification (Condair & Jumag)
- Spray Humidification (Adiabatic – Condair): An option for large air volumes where natural cooling of the space is also required, reducing the load on air-conditioning systems.
- Steam (Jumag): Used where hygiene and accuracy of ±2% are critical, such as in the food or pharmaceutical industries, where sterile steam guarantees air purity.
Dehumidification (Condair)
- Condensation: Suitable for halls with moderate temperatures, where water is removed by cooling the air below the dew point.
- Adsorption: The recommended technology for cold stores or logistics warehouses, capable of removing moisture even at temperatures below 0°C.
How do you choose the right system?
To avoid investing in solutions that do not work, the decision-making process must include a detailed analysis of the technical specifications.
Checklist for making the right decision:
- Hall volume and air flow: Determine the required capacity of the equipment to avoid undersizing.
- Type of activity: Humidity requirements differ radically between wood processing and electronics manufacturing.
- Budget and ROI: Analyse the initial investment in relation to the reduction in scrap costs and equipment maintenance costs.
- Maintenance and support: Access to spare parts and rapid technical support to minimise production downtime.
At Texco, we assess these variables to provide ready-to-implement solutions that ensure predictable delivery and clear implementation timelines, removing uncertainty from the process of modernising your industrial or production space.
Working with a supplier who understands industrial projects enables technical decisions based on concrete data from the analysis of specifications. The value of a partnership with Texco stems from design tailored to technical specifications to prevent equipment sizing errors, from the assessment of implementation and stock levels to ensure deadlines are met, as well as from maintenance and technical support that minimise production downtime.
Request a technical analysis of the microclimate and identify the Condair and Jumag solutions tailored to your hall’s specifications! Our team has the necessary expertise in relative humidity control and diagnostic, design and maintenance services in Romania, the Republic of Moldova, Ukraine and Morocco! Call us on +40 736 369 802 or email us at office@texco.ro!
Frequently Asked Questions
No. Standard HVAC systems primarily control temperature. To maintain RH within strict ranges (±5%), dedicated humidification or dehumidification solutions are required.
Through high-capacity industrial systems (adiabatic or steam-based) integrated with sensors and HVAC automation, which adjust RH in real time according to temperature and load variations.
In most industrial applications, the safe range is 40–60% RH. Sensitive processes (pharmaceuticals, electronics, printing) may require stricter tolerances.A technical inspection every 6–12 months is recommended, along with continuous monitoring via sensors. Predictive maintenance reduces the risk of unplanned downtime. Problems such as static electricity, material cracking, weight loss in wood/textiles and staff discomfort may occur. In printing and packaging facilities, frequent blockages may occur. Condensation, corrosion, mould, material deformation and damage to packaging may also occur. In metal and logistics warehouses, direct stock losses may occur.
- Adiabatic – more energy-efficient, suitable for large halls and temperature-sensitive materials.
- Steam – preferred where hygiene, precision and strict control are critical (food, pharmaceuticals).
In cold stores, refrigerated warehouses or spaces below 10°C, where condensation-type dehumidifiers lose their efficiency. The volume of the hall, air flow, type of process, level of automation and hygiene requirements. ROI is calculated primarily through the reduction in scrap and unplanned maintenance.