Dryer Retrofit – the Alternative to New Investment
For many years, Phoenix Contact has pursued the goal of continuously increasing the energy efficiency of its electroplating plant. Together with Richard Tscherwitschke GmbH, the company has now implemented a comprehensive retrofit project that brings its more than 30 year old dryers up to modern standards.
A complete replacement of the dryers would have resulted in extended production downtime. Thanks to the retrofit measures, Phoenix Contact was able to significantly improve energy efficiency while continuing to use the existing equipment.
Implemented Measures
- Intelligent exhaust air control: A humidity controlled exhaust air system was integrated into the dryers. The previously manual flap mechanism is now motor driven and automatically regulated. At the beginning of the drying process, moist air can escape more quickly. Once a predefined relative humidity level is reached, the flaps close automatically to keep dry air and thermal energy inside the dryer. This reduces energy consumption by approximately 10–15%.
- More powerful, frequency controlled fans: New fans with frequency control improve air circulation and accelerate heat transfer to the goods. Their output can be adjusted to reduce energy consumption and noise levels, especially during loading and unloading of the barrel units.
- Automated dryer lids: Previously, the drying chambers operated without lids, allowing heat to escape unused. As part of the modernization, automated lids were added, helping retain heat and further reduce energy consumption.
- New barrel inserts and optimized liquid removal: The redesigned barrel inserts improve airflow through the plating barrels. heir improved construction increases service life while reducing maintenance requirements. Improved airflow removes residual water from the goods and the barrel surfaces more effectively. The geometry also ensures that introduced liquid is discharged quickly and efficiently. The less liquid that remains in the dryer, the less energy is required for drying.
Retrofit Instead of New Equipment – A Deliberate Decision
The dryers at Phoenix Contact are centrally integrated into the plant. Replacing them would have required dismantling adjacent components and would have caused long downtime. Retrofit was therefore the most economical and technically sensible solution. The modernization was completed during ongoing production, and the investment will pay off quickly.
Conclusion
With the modernization of its dryers, Phoenix Contact demonstrates a strong commitment to sustainable electroplating production. The dryers now operate more efficiently, are easier to control, and can be maintained with current spare parts. This reference project shows how retrofit measures can be a viable alternative to purchasing new equipment—especially when the existing plant structure should remain in place.
>> full article in Galvanotechnik 07/2026 (in German)
