Field Engineering Introduction:

Same Drier. New Ideas. New Solutions.

Our Field Did You Know:

Engineering
Department has • The average convection conveyor drier operates 10%-30% below
conducted over 1000 expected efficiency and capacity?
• Many times critical energy losses are not even noticed because they
detailed drier are not found through typical operational measurements.
evaluations over the • If your drier is not achieving a high moisture tolerance, then you may
last fifteen years and be wasting a substantial amount of energy to over dry some product
has found that most and, more importantly, could be losing hundreds of thousands of
dollars each year on just one small drier.
of those driers were • It is not uncommon to find that a simple operational change can save
operating at 10% to enough money on one line to not only pay for the evaluation service,
30% below expected but to pay for the drier itself in one year.
• The average results of our evaluations improve energy efficiency by
efficiency and
10% and possibly as much as 50%. This results in enough money to
capacity. recover the cost of the evaluation within weeks.

Feedback from the field:

“Aeroglide associates have been very helpful during the past two years in assessing the
problems with a polymer dryer which cannot achieve the design capacity. Their
recommendation...has been successful in achieving higher rates. They were also helpful in
sharing dryer knowledge and troubleshooting techniques with our engineers.”
Technical Manager, Goodyear Tire and Rubber Company

“Your dryer knowledge and expertise helped us immensely....Through your visit we have
increased our dryer knowledge…….help us understand how to maintain and improve our dryer in
the future.”
Waste Reduction Team, Kellogg Canada, Inc.

“The Aeroglide Drier Evaluation Program has proven to [be] a very valuable tool for helping our
company access the true capabilities of our existing drying equipment….We would recommend
Aeroglide’s Drier Evaluation Program to anyone in need of technical assistance for their drying
operation.”
Engineer, Jilin Chemical Industry Corporation

“The drier audit program from Aeroglide gave Nantex a real overview of the concepts for self-
assessment of air drier performance profile. Recently drier capacity has been up 10% through
those concepts….”
Vice Plant Manager, Nantex Industry Company

Educate • Evaluate • Enhance

 Evaluation Project Scope:
Detailing the evaluation procedure.

We encourage the Typical Scope: Assistance:

A. Meet briefly with primary Typically one (1) helper is required to assist
participation of our technical personnel to review in the evaluation process. However, it is
customers during the current conditions, perceived highly recommended to involve anyone who
drying issues, pertinent desires to learn more about basic drier
data collection operational data, and goals of the operation.
process. This is a evaluation.
great learning B. Begin the drier evaluation to Special Equipment:
assess current conditions. A. Aeroglide Responsibility: All test
opportunity. 1. Drier Shutdown & Cooled for equipment unless otherwise specified.
Inspection: Conduct complete B. Customer Responsibility: Ladders,
physical inspection with a flashlights, safety equipment, moisture
focus on how the mechanical measurement capabilities, and/or small
make-up of the drier affects hand tools.
the drying process.
2. Drier In Operation: Collect Terms and Conditions:
process data that will enable A. Charges: US $2400 per drier plus
us to better understand the traveling and living expenses. This
operation and general health charge includes time required for data
of the drier. analysis and report generation
C. Make short-term system conducted off-site after the evaluation.
adjustments based on drier data B. Travel Charge: US $50 per hour (not to
(if possible). exceed US $1500)
D. Review data and prepare for C. Terms: Net 15 days.
summary meeting. D. Purchase Order: Required prior to
E. Conduct summary meeting to customer billing.
review initial data results and
preliminary recommendations. Contact Information:
Dustin O’Farrell, Manager, Field Engineering,
(Return to Aeroglide): at +1.919.851.2000 or
F. Perform necessary calculations, [email protected]
re-analyze the data collected, and
discuss with other Aeroglide Satisfaction Guarantee:
engineers to provide the best If you are not completely satisfied with your drier
possible set of recommendations. evaluation, Aeroglide will rectify all concerns
(returning to your site if necessary) or void all
G. Submit final report and charges.
recommendations approximately
two weeks after all process data
is received.

Educate • Evaluate • Enhance

 Sample Evaluation Report Format:
Below is an example of an observation made during an evaluation.

Observation No. (Sample)

Oscillating spout feeder may need slight adjustment.

Theory:

Even and consistent bed loading across the width and depth of the product bed is critical to the
drying process. Typically, inconsistent drying accompanies inconsistent bed loading.
Specifically, the lightly loaded areas of the bed represent less static resistance; therefore, the air
will take the path of least resistance through these areas. Since more airflow means more drying
(or cooling - depending on the application), the lightly loaded areas are over-dried while the
heavily loaded areas are under-dried (and under-cooled).

Reason:

It appeared as though the oscillating feeder was allowing some of the product build-up on the
stationary side guide immediately before the cooler inlet. Some product was spilling over the
stationary side guide into the area where the sprocket is located.

Indicator(s):

Visual Inspection.

Solution(s):

Slightly reduce sweep of oscillating spout feeder if problem continues. When adjusting, try to
maintain an even product bed depth across the width of the cooler.

Left: An
illustration of
the effects of
product loading
on airflow.

More Pressure, More Short-Circuiting

Educate • Evaluate • Enhance

 Drying Theory Training:
Training to suit the customer’s needs as well as a perfect compliment to a drier
evaluation project.

The most common area of drier inefficiency is poor drier operation. Often times, a
We have conducted simple process change can dramatically increase production rates while decreasing
practical drying energy costs. The courses that we teach are designed to help you recognize the
classes throughout problem areas and to give you the knowledge to make the correct adjustments to
improve the process.
the world and have
found them to be a In the case of a corporate class, there are three (3) basic training options that can be
held at your preferred facility. All courses will cover the same basic material but the
valuable tool in level of detail and amount of hands-on work will be dependent on the format. We also
improving the conduct multiple industry wide training seminars which are three (3) days in length and
customer’s process. are held at Aeroglide’s Technical Center in Raleigh, NC, as well as other selected sites
in Europe, Asia, and South America. Please reference the following course options:
This is often where
hidden mysteries are • Half-Day Basic Drying Theory & Application Class (Customer Site)
discovered and • Full-Day Basic Drying Theory, Application & Trouble-Shooting Class (Customer Site)
• Multi-Day Customized Drying Training Seminar (Customer Site)
solved. • 3-Day Drying Training Seminar – “Drying Theory Put to Practice” (Location Varies)
• 3-Day Drier Maintenance Seminar – “Drier Maintenance: A Practical Approach”
(Aeroglide Technical Center – USA only)

Feedback from the classroom:

“It’s practical, intensive and very enjoyable. This is an excellent
opportunity to meet with professionals from different areas.”
Quaker Oats Company

“I am impressed with Aeroglide’s technical expertise and your

ability to apply your knowledge – You know drying!”
Hill’s Pet Nutrition

“The professional approach and preparation showed the high

level of technical knowledge…”
Cargill Honduras

“…information was invaluable and the hands-on classroom

structure worked really well.”
Celanese Corporation

Educate • Evaluate • Enhance

 Half-Day Basic Drying Theory & Application Class
Customer Site

This is a class that Who Should Attend? Typical Material Covered May Include:
Plant Engineers, Product I. Drying Basics
will cover the basics Development, Operators, A. Drying Theory
of drying and should Maintenance, and Quality Control B. Drier Control Parameters
give the operations Personnel that wish to better 1. Airflow
understand their drying process. 2. Humidity
personnel confidence 3. Temperature
to make adjustments How you will benefit: C. Drier Operation/Adjustments
• Gain valuable knowledge of drying 1. Humidity
that will save money theory basics. 2. Bed depths
and make a higher • Relate drying theory to your 3. Retention time
quality product. product. 4. Temperature
• Develop basic trouble-shooting 5. Balancing the drier
skills to begin to understand your D. Understanding Airflow
drier(s) and bring about
improvements. II. Process Troubleshooting
• Understand the airflow of your A. Airflow Short-Circuits
drier(s) and the effects of internal B. Optimizing Bed Heights & Bed
baffling. Speeds
• Learn to operate the drier in best C. Optimizing Operating Humidity
practice methods to achieve
higher quality products and III. Drier Parameters: “Cause and Effect”
improved energy efficiency. Open Discussion on the cause and
• Identify the most common drier effect of different changes to the
pitfalls.
process parameters – retention time,
Terms and Conditions: product temperatures, recirculation
Cost: US $1200 plus travel and air humidity, etc.
expenses. Note that this course is
normally taught in conjunction with a
drier evaluation project or a pre-
planned customer visit.

Special Equipment:
All equipment for the training will be
brought by Aeroglide except for LCD
projector, which is required for the
presentation.

Educate • Evaluate • Enhance

 Full-Day Basic Drying Theory, Application &
Trouble-Shooting Class
Customer Site

In addition to helping Who Should Attend? Typical Material Covered May Include:
Plant Engineers, Product I. Drying Basics
form a good Development, Operators, A. Drying Theory
understanding of Maintenance, and Quality Control B. Drier Control Parameters
drying basics, this Personnel that wish to better 1. Airflow
understand their drying process. 2. Humidity
course focuses on 3. Temperature
developing a “hands- How you will benefit: C. Drier Operation/Adjustments
• Gain valuable knowledge of drying 1. Humidity
on” comfort with theory basics. 2. Bed depths
data collection and • Relate drying theory to your 3. Retention time
analysis critical to product. 4. Temperature
• Develop the skills to effectively 5. Balancing the drier
the understanding evaluate your drier(s) and produce D. Understanding Airflow
and day-to-day a baseline for improvements.
• Learn to operate the drier in best II. Process Troubleshooting
optimization of your practice methods to achieve A. Airflow Short-Circuits
drying process. higher quality products and B. Optimizing Bed Heights & Bed
improved energy efficiency. Speeds
• Identify the most common drier C. Optimizing Operating Humidity
pitfalls.
III. Evaluation Techniques
Terms and Conditions: A. Data Collecting
Cost: Based on the number of B. Trouble Shooting
attendees and pre-determined course
material, plus travel and living IV. Equipment Inspection
expenses. A. Inspect a drier
B. Collect basic evaluation data
Special Equipment:
All equipment for the training will be V. Data Compilation & Review
brought by Aeroglide except for LCD Review evaluation data and determine
projector, which is required for the what are the areas of improvements.
presentation.
VI. Field Data: Analysis of the Effects on
Drier Performance

Educate • Evaluate • Enhance

 Multi-Day Customized Drying Training Seminar
Customer Site

This is a “hands-on” Who Should Attend? Typical Material Covered May

Plant Engineers, Product Development, Include:
class which focuses Operators, Maintenance, and Quality :
on putting classroom Control Personnel that wish to better Day 1:
knowledge to understand their drying process. I. Drying Basics
A. Why do we dry?
practice. You will How you will benefit: B. Drying Theory
leave here with the • Gain valuable knowledge of drying C. Operating Parameters
theory basics. 1. Humidity
skills and application • Relate drying theory to your 2. Bed depths
knowledge to be product. 3. Retention time
• Develop the skills to effectively 4. Temperature
more confident that evaluate your drier(s) and produce D. Balancing the Drier
your adjustments to a baseline for improvements. E. Drier Evaluation
your drier will be the • Learn to operate the drier in best F. Drier Mechanical Inspection
practice methods to achieve higher G. Drier Trouble-Shooting
right ones. quality products and improved H. Drier Simulation
energy efficiency.
• Identify the most common drier II. Process Troubleshooting
pitfalls. A. Airflow Short Circuits
B. Optimizing Bed Heights & Bed
Terms and Conditions: Speeds
Cost: Based on the number of C. Optimizing Operating Humidity
attendees and pre-determined course
material, plus travel and living Day 2:
expenses. III. Drier Evaluation Simulation
A. “Inspect a Drier”
Special Equipment: B. “Collect Evaluation Data”
All equipment for the training will be C. “Analyze Evaluation Data”
brought by Aeroglide except for LCD
projector, which is required for the IV. Drying Basics Continued
presentation. A. What is Airflow?
B. Understanding the Value of
Moisture Uniformity
C. Developing a Drying Curve

V. Overall Course Review

Educate • Evaluate • Enhance

 3-Day Drying Training Seminar – “Drying Theory Put to Practice”
Locations Vary

Who Should Attend? Typical Material Covered May Include:

This course represents Plant Engineers, Product Development, Day 1:
Operators, Maintenance, and Quality I. Drying Basics
a “hands-on” intensive Control Personnel that wish to better A. Why do we dry?
review of everything understand their drying process. B. Drying Theory
from drying basics to C. The Perfect Drier
How you will benefit: D. Operating Parameters
advanced trouble- • Gain valuable knowledge of drying 1. Humidity
shooting. The ability to theory basics. 2. Bed depths
• Relate drying theory to your products. 3. Retention time
use actual test • Develop the skills to effectively 4. Temperature
equipment and small evaluate your drier(s) and produce a E. Balancing the Drier
scale functioning driers baseline for improvements. F. Drier Evaluation
• Learn to operate the drier in best G. Mechanical Inspection
during the seminars, practice methods to achieve higher H. Process
allows us the quality products and improved energy Measurement/Adjustment
efficiency. I. Drier Trouble-Shooting
opportunities to apply
• Identify the most common drier pitfalls.
techniques developed • Be exposed to the latest technology in II. Drying Simulation
in the classroom to drying. A. Drier Optimization

actual lab practices. Terms and Conditions: Day 2:

Cost: Cost varies with location. (Course III. Advanced Drying Concepts
materials, notebook, group meals, and A. What is Airflow?
March 3-5, 2008 B. Understanding the Value of
evening activities are included.) To
Bangkok, Thailand register please call + 1-919-851-2000 and Moisture Uniformity
ask for Lynn Young or email your C. Developing a Drying Curve
information to: [email protected]. D. Economics of Drying
April 1-3, 2008 E. Drier Controls and
Barcelona, Spain Location and Accommodations Instrumentation
These courses will be held at the
Aeroglide Technical Center in Raleigh, IV. Lab Practices
October 21-23, 2008 NC or other international locations and A. Pitot Traverse, Pressure Drop
Puerto Vallarta, Mexico are open to an industry wide customer and Fan Curve Estimation
base. B. Wet Bulb/Dry Bulb Measurement
C. Drying Curve Development
December 9-11, 2008 Professional Engineering Credit:
Aeroglide is an approved sponsor of Day 3:
Raleigh, NC, USA V. Heat and Mass Balance
Continuing Professional Competency
(CPC) activities for Professional
Engineers and Surveyors licensed by the VI. Overall Course Review
State of North Carolina. This course will
be worth 17 PDHs (Professional
Development Hours).

Educate • Evaluate • Enhance

 3-Day Training Seminar – “Drier Maintenance: A Hands-on Approach”
Aeroglide Technical Center, Raleigh, NC USA

Who Should Attend? Typical Material Covered:

This course represents Maintenance Managers, Maintenance
Day 1:
a “hands-on” intensive Personnel & Operators that wish to
I. Introduction
better understand and troubleshoot
review of everything their drier in daily operation.
II. Drying Basics
A. Drying Theory
from drying basics to B. Drier Operation/Adjustments
How you will benefit:
advanced trouble- • Identify the most common drier III. Drying Application
shooting. The ability to pitfalls and gain valuable A. Evaluation Techniques
knowledge of drying theory basics. B. Data Collecting
use actual test IV. Lab Practice
• Understand how your drier should
equipment and small be maintained on day-to-day and • Bench top Product Testing
V. Drier Mechanical Review
scale functioning driers long-term basis.
A. Mechanical Inspections
• Develop the skills to effectively
during the seminars, evaluate your driers and B. Bed Assemblies/Repair
allows us the understand what components VII. Shop Tour
opportunities to apply should be repaired or replaced.
• Gain a better understanding of Day 2:
techniques developed in your steam, gas & electrical VI. Steam Systems
the classroom to actual systems and learn the • Class Review
troubleshooting skills needed to • Lab Section
lab practices. identify and troubleshoot common Presentation and lab session performed by
Carolina Steam Systems with Mobile Steam
issues.
Training Lab Unit.
June 3-5, 2008 • Increase your awareness of VII. Gas Burners
preventative maintenance,
Raleigh, NC, USA ancillary equipment, and bed
• Class Review
assemblies. • Lab Section
Presentation and lab session performed by Maxon
Terms and Conditions: with burner demonstration.
Cost: US $2000. This course is VIII. Electrical Systems
scheduled for June 3-5, 2008. (Course • Class Review
materials, notebook, group meals, and • Lab Section
evening activities are included.) To Presentation and lab by Aeroglide Electrical
register please call + 1-919-851-2000 Engineering Department focused on issues
commonly encountered in the field.
and ask for Lynn Young or email your
information to:
[email protected] Day 3:
IX. Advanced Drier Mechanics
Location and Accommodations X. Drier Preventive Maintenance
This course will be held at the Program
Aeroglide Technical Center in Raleigh, XI. Drier Simulator
NC and is open to an industry wide XII. Private Question Session
customer base. (Optional)
An optional time for you to ask questions
Professional Engineering Credit: about your individual process in private.
Aeroglide is an approved sponsor of
Continuing Professional Competency
(CPC) activities for Professional
Engineers and Surveyors licensed by
the State of North Carolina. This
course will be worth 17 PDHs
(Professional Development Hours).

Educate • Evaluate • Enhance