Project: Roller dryer

The challenge

The challenge in this project lay in the mechatronic and software integration of new, advanced functionalities within an existing machine concept. Standard roller dryers often lack the fine control needed for a perfectly homogeneous and stable product flow. Controlling the drying process required real-time monitoring and precise control of five critical variables: the exact temperature of the roller surface, roller gap control, rotation speed, the volumetric flow of the organic material, and perfectly even material distribution across the roller.

The solution from High Tech Alliance consisted of a targeted, modular optimisation. Because developing such specific functions is custom work, our engineers first worked out various innovative concepts during the development phase and tested them using physical test setups. Only once the operation had been conclusively proven were the high-precision features built and installed. The dryer is now equipped with smart sensors and control software that continuously fine-tune the parameters, so the organic material is dried under perfectly controlled conditions.

The role of High Tech Alliance

In this case, our main added value lay in the conceptual strength of our engineers. Instead of designing a costly, entirely new machine, we upgraded the existing installation in terms of both hardware and software. This pragmatic approach minimised the required investment, resulting in an exceptionally short Return on Investment (ROI) for the client.

Solution and result

Thanks to the thoroughly tested concepts and precise process control, the client now has a unique roller dryer that delivers consistently high product quality. The optimisation gains are directly measurable on the shop floor, with an efficiency improvement of 20% to 25%.