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A vacuum dryer is a material drying technology used in the plastics industry to remove moisture from plastic resins or pellets before processing.
Unlike conventional dryers, vacuum dryers operate at lower temperatures, significantly reducing the risk of thermal degradation to the plastic. Vacuum dryers do this by creating a low-pressure environment which effectively lowers the boiling point of water, allowing for faster and more thorough drying of the plastic materials with reduced material degradation.
The use of vacuum dryers is crucial in the production of high-quality plastic products, preventing defects that can be caused by excess moisture during manufacturing processes. This is particularly important for hygroscopic plastics, which readily absorb moisture from the air.
The Ultimate ULTRA Drying Solution, the Maguire ULTRA dryers have demonstrated the ability to accelerate plastic drying 6x faster compared to traditional dryers, all while utilising up to 70% less energy.
This rapid drying innovation employs a vacuum-based approach without the need for desiccants, which is particularly well-suited for optical, medical and technical applications. The vacuum batch dryer series presents a remarkable 70% reduction in power consumption compared to dehumidifying methods.
Desiccant dryers consume approximately 45 watts per pound per hour (100 watts per kilogram per hour) of material processed. In comparison, Maguire ULTRA Dryers use only 4 watts per pound per hour (8 watts per kilogram per hour), translating to significantly lower energy consumption.
To put this into perspective, in a typical plastics drying line running at a throughput of 220 pounds per hour (100 kilograms per hour), a generic desiccant dryer would consume an additional 41 watts per pound (92 watts per kilogram) compared to an ULTRA Dryer.
In fact, what energy a desiccant dryer consumes in just one day, an ULTRA Dryer would spread out over the course of an entire week. This not only lowers operational costs but also contributes to long-term sustainability by reducing your facility’s overall energy usage. These huge year-on-year energy savings make ULTRA Dryers an excellent choice for those looking to improve efficiency while maintaining high-quality drying performance.
At Summit Systems, we proudly present ourselves as the exclusive suppliers of the renowned Maguire range of Vacuum Dryers and Blenders in the UK. We understand the diverse needs of your industry. Gain access to expertise that can help tailor the ULTRA dryer’s capabilities to your specific requirements, with our team always available to support you.
The material is first loaded into a heating hopper to come up to the normal desired drying temperature for that material – for PET typically 40 to 60 minutes at a drying temperature of 1 338°F / 170°C.
The preheated material then feeds by gravity into the vacuum chamber. The amount of material is monitored by a pair of load cells to know the amount of material and adjust if required. A high vacuum is applied to 700 mmHg (90% vacuum) and the material is held under vacuum for 20 to 30 minutes, depending on the material type, initial moisture and required throughput.
The material is fed to the material retention hopper which is also monitored by load cells. The load cells monitor usage and signal when to feed from the vacuum hopper.
The membrane dry air purge option provides a supply of -40°F / -40°C dew point air to purge the vacuum chamber and blanket the retention hopper.
Vacuum dryers, such as the Maguire ULTRA Dryer, are significantly more energy-efficient, using up to 70% less energy than traditional desiccant dryers. Vacuum dryers can also operate at lower temperatures, reducing thermal degradation of the plastic while drying.
They also offer faster drying times due to the reduced pressure, which lowers the boiling point of moisture and accelerates its removal from the plastic material. Additionally, vacuum dryers have the advantage of not relying on desiccant beds, which require regular regeneration and maintenance.
Vacuum drying is incredibly efficient, particularly when compared to desiccant drying methods. This translates into substantial energy savings, making vacuum drying a highly efficient option for plastic processing operations. The efficiency also extends to faster drying times, which improves throughput and reduces downtime.
The initial investment in vacuum drying equipment may be higher than for traditional desiccant dryers, but the energy savings and reduced operational costs quickly offset this upfront expense.
With vacuum drying consuming significantly less energy, running costs are much lower, with the savings increasing over time. Additionally, vacuum dryers tend to require less maintenance, further reducing long-term costs.
Unlike traditional desiccant dryers, the Maguire ULTRA Dryer does not operate based on a dew point measurement.
Dew point, which is critical in desiccant drying to measure the dryness of the air, is not relevant in vacuum drying. The ULTRA Dryer removes moisture through a high-temperature, low-pressure vacuum process, so instead it monitors live vacuum pressure.
Learn more here: https://www.youtube.com/watch?v=J6UhPlytgYM.
Maguire ULTRA Dryers require minimal maintenance – particularly when compared to desiccant dryers. There are no desiccant beds to regenerate, which eliminates the need for periodic replacement or reactivation.
The ULTRA Dryer’s simple and robust design focuses on long-term reliability with fewer moving parts and less wear and tear. Regular maintenance only involves simple routine checks, such as inspecting vacuum seals and ensuring that components like filters and heating elements are functioning properly. Overall, the maintenance requirements are straightforward and less frequent, reducing downtime and operational costs
One day, they likely will be. Maguire has been a pioneer in vacuum drying technology since 1998, continuously refining and improving their designs over three generations of dryers. Over the past 26+ years, the advantages of vacuum drying are becoming more apparent across various applications.
Vacuum dryers like the Maguire ULTRA Dryer are increasingly being chosen over traditional desiccant dryers. As the efficiency and performance of vacuum drying become widely recognised, it is expected to become the preferred method for drying plastics.
