Eliminating moisture and humidity in a bakery manufacturing plant

For over 30 years, a renowned artisan bread manufacturer has been dedicated to producing high-quality, authentic bread using sustainable practices. Their team of skilled bakers meticulously oversees every aspect of production to ensure exceptional results.

When outdoor humidity levels threatened operations in the spring of 2024, the facility faced concerns over worker safety, product quality, and potential revenue loss. Facility managers promptly sought an effective solution to restore optimal conditions and prevent costly disruptions.

CHALLENGE

Elevated moisture levels were creating a myriad of problems. First, condensation was settling on the cold dock floors and entryway into the freezer making the path slippery. Second, foggy and cloudy conditions developed in the cold dock area slowing down production processes (shown in picture below).

Additionally, the storage freezer built up a thick layer of frost which spread to evaporators and floors, disrupting the efficiency of their cooling systems. Condensation formed on walls and ceilings, leading to potential quality control issues and raising the risk of regulatory violations. Lastly, a man door froze open creating an open pathway for moisture to enter the freezer further straining the infrastructure to keep up production.

The bakery urgently needed a quick and effective solution to mitigate these problems and avoid further production delays. They contacted Industrial Conditioning Equipment (ICE), an independent seller of Munters dehumidification and climate control equipment. ICE then introduced them to Polygon, with whom they rely for temporary solutions.

SOLUTION

To address the moisture challenges at hand, Polygon installed an HC-4500 electric desiccant dehumidifier, which conditions 100% recirculating air. The dehumidifier effectively eliminated the moisture, consequently getting rid of the fog and ice that had been accumulating on the floors. Additionally, the persistent frost build-up inside the freezer substantially improved, and the functionality of the mandoor was restored, allowing for more efficient operation of the freezing process.            

Ryan Flynn, Sales Engineer at Industrial Conditioning Equipment, LLC, expressed his satisfaction, stating, "I can always rely on the Polygon team to assist me in providing clients with quick and effective solutions. It has been great working with the Polygon techs and receiving their timely support." He added, "The bakery can now focus on producing top-quality artisan bread."

The reduction and elimination of frost build-up inside the freezer and evaporator coils allowed the coils to operate efficiently, resulting in less wasted energy.

RESULTS

Business continuity –Polygon quickly installed the dehumidifier and immediately resolved the issues of fog, ice, and frost. This ensured continued operations without requiring an investment in long-lead-time capital equipment. 

Reduced safety hazards –Polygon was able to reduce safety hazards such as slippery floors, fog, and ice build-up. This created a safer working environment for employees and minimized the risk of workplace accidents.

Energy Efficiency - Restoring the functionality of the freezer door improved processes and avoided excessive energy usage due to running an inefficient system.

Learn more about how Polygon can help control climate conditions in food production and manufacturing facilities.