Solving Overheating Issues in Industrial Dryers: A Technical Overview

In the realm of industrial printing and production, managing equipment efficiently is paramount to ensure both quality and productivity. One common challenge that arises is dealing with overheating issues in industrial dryers, such as the Workhorse 2608P. This problem not only affects the quality of the output but can also lead to significant downtime and increased operational costs. Let's delve into a practical approach to diagnosing and resolving such issues, drawing insights from a real-world scenario involving a used Workhorse 2608P dryer.

Understanding the Problem

The Workhorse 2608P, known for its robust performance and efficiency, encountered a problem where it started running too hot, scorching the materials it was supposed to dry. The situation was exacerbated despite replacing the thermocouple, a component crucial for temperature measurement. The dryer's set value (SV) was reading at 320, while the process value (PV) only reached about 155. An infrared thermometer reading showed ink temperatures exceeding 400 degrees, well above the desired range. This discrepancy highlighted a significant issue in temperature regulation, necessitating a closer examination.

Diagnosing the Issue

The first step in addressing this challenge involves checking the temperature sensor wiring all the way to the controller. Faulty wiring could lead to inaccurate temperature readings, causing the dryer to overcompensate and overheat. If the wiring checks out, the next recommendation is to consider replacing the controller. Controllers are generic components that can be sourced affordably, with replacements available for as low as $20 on platforms like eBay. The key is ensuring compatibility with the existing system.

Exploring Solutions

Upon further analysis, an experienced dryer repair specialist suggested that replacing the problematic cal rods with ceramic panels could significantly reduce both the amp draw and the operational cost per hour. This change not only addresses the overheating issue but also enhances the dryer's efficiency. Adjusting the belt speed on the dryer to reduce the duration materials spend under the heater was another practical solution. For instance, increasing the belt speed by 10% and continuously monitoring until the optimal curing zone is achieved could mitigate overheating problems. This adjustment allows for a higher throughput of materials, indirectly boosting productivity and profitability.

Moreover, it was noted that sourcing a controller specifically programmed for infrared panels, as opposed to cal rods, might involve a higher expense. However, the investment in a tailored solution like the Vastex LittleRed dryer, renowned for its reliability and performance, presents a long-term benefit outweighing the initial cost.

Leveraging Professional Advice and Upgrades

The narrative concludes with the installation of a new Vastex LittleRed dryer, which provided a remarkable improvement in performance and reliability. This upgrade underscores the importance of not only addressing immediate technical issues but also considering long-term operational efficiency and quality output.

Solving overheating issues in industrial dryers requires a systematic approach, starting from basic diagnostics to more complex upgrades or replacements. Engaging with experienced professionals and considering their advice can lead to effective solutions that enhance both productivity and quality.

For more technical insights and problem-solving tips in the industrial production space, we invite our readers to follow our YouTube Channel at BCH Technologies, visit our tech blog, or if you're in the vicinity, drop by our local office in Greensboro, North Carolina. We're dedicated to providing practical, actionable advice to help you navigate the challenges of industrial equipment management and optimization.