{"id":1870,"date":"2014-12-04T21:18:32","date_gmt":"2014-12-04T21:18:32","guid":{"rendered":"https:\/\/www.insta-pro.com\/?p=1870"},"modified":"2025-12-18T10:23:29","modified_gmt":"2025-12-18T16:23:29","slug":"calculating-drying-costs-and-heat-needs","status":"publish","type":"post","link":"https:\/\/instapro.spinuhost.com\/en\/blog\/businessstrategyandfinance\/calculating-drying-costs-and-heat-needs\/","title":{"rendered":"Calculating Drying Costs and Heat Needs"},"content":{"rendered":"

Plant investments can vary from initial capital investments to ongoing costs.\u00a0 This is why our sales team<\/a> devotes time to conduct a feasibility analysis with you.\u00a0 We are then able to recommend a system that will allow you and your business to be successful.<\/p>\n

For example, in fish and pet food production, a dryer\/cooler<\/a> is a must have.\u00a0 The moisture percentage of the product coming out of the extruder is higher than a typical safe level for storage, so drying\/cooling equipment becomes a necessity.\u00a0 The question then becomes “How much energy do you need to do this?\u00a0 Below is a formulation that will assist in predicting the ongoing costs.<\/p>\n

Incoming Water Amount<\/strong><\/p>\n

Let\u2019s assume we have a product that leaves the extruder at 20% moisture at a rate of 2200 pounds\/hr (1 metric ton\/hr).\u00a0 We want to dry this down to 10% moisture coming out of the dryer\/cooler so that it is safe for bagging and storage.\u00a0 It\u2019s important to note the dry matter weight of the product as this will stay constant since we are only trying to remove moisture.<\/p>\n

Solving for dry matter weight gives:<\/p>\n

0.8 x 2200 lbs = 1760 lbs (dry matter)<\/p>\n

This means we have 440 lbs of water in the product (2200-1760 or 20%)<\/p>\n

Final Water Amount<\/strong><\/p>\n

In order to determine energy consumption of drying, we will need to determine how much water will be evaporated during the drying process.\u00a0 Since we know the dry matter weight (1760 lbs) and the final moisture percentage (10%), we can calculate the amount of water leftover in the final dried product.<\/p>\n

We know that at 10% moisture, 90% of the final product is dry matter.\u00a0 We simply divide our dry matter weight by 90%:<\/p>\n

1760 lbs \/ 0.9 = 1956 lbs<\/p>\n

This is the final weight of the product coming out of the dryer at 10% moisture.\u00a0 We now know \u00a0 \u00a0 \u00a0starting and ending weights of the product, so subtracting these will show how much water is evaporated during this process:<\/p>\n

2200 lbs \u2013 1956 lbs = 244 lbs (water\/hr removed)<\/p>\n

Note: we can verify this by subtracting this from our initial water weight (440 lbs) and dividing by ending weight (1956 lbs): (440 \u2013 244) \/ 1956 = 10%<\/em><\/p>\n

BTUs<\/p>\n

As a rule of thumb, it takes about 1500-1800 BTU to vaporize one pound of water.\u00a0 Let\u2019s assume it takes 1800 BTUs for a conservative calculation.\u00a0 We need to remove 244 lbs of water per hour, so the amount of BTUs required is:<\/p>\n

1800 BTU\/lb x 244 lbs\/hr = 439,200 BTU\/hr<\/p>\n

You can use this in cost estimations for utilities and equipment sizing (dryer\/coolers, boilers, etc).\u00a0 Initial capital investments are important considerations, but ongoing costs such as this must be taken into account as well.\u00a0 This is a perfect opportunity for a feasibility analysis!<\/p>\n

 <\/p>\n","protected":false},"excerpt":{"rendered":"

Plant investments can vary from initial capital investments to ongoing costs.\u00a0 This is why our sales team devotes time to conduct a feasibility analysis with you.\u00a0 We are then able to recommend a system that will allow you and your business to be successful. 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