New OPTI-DRY 3.0 System Gives Maximum Control of Dryer Performance

We’ve just launched a new optimisation system to give maximum control of dryers used in manufacturing processes including print, packaging and tissue industries.

The new OPTI-DRY 3.0 system has been developed following requests from businesses who want better control of energy consumption, waste and environmental impact.

OPTI DRY machinery

It also offers compliance with the latest flammable substance safety standards and the ability to remotely monitor print and drying processes on a continual basis.

OPTI-DRY 3.0 makes it easier to make adjustments, and improve the quality of print, packaging and paper products. The monitoring system is PC based and provides users with clear data and graphs showing the performance and optimisation of print, drying and abatement processes, with the ability to remotely monitor performance.

Paul Morrall, an electrical engineer at Operational UK, said: “As one of the world’s major innovators in the field of optimisation for dryers and ovens, Operational Group can supply answers to all types of production and environmental problems.

“Issues we routinely address include optimising dryers for rotogravure, flexographic and web-offset printing, as well as coating and lamination for the paper and tissue industries. In any context in which heat is used to drive off moisture or solvents, we can apply highly effective improvements.

OPTI DRY Machinery close up

“In an increasingly competitive modern environment, Operational’s dryer and process optimisation services can deliver on multiple objectives for your business. As well as effectively reducing energy consumption and related costs, we can help improve product quality, increase production speeds and reduce exhaust gas emissions – effectively increasing your productivity and reducing your carbon footprint.”

Paul highlighted five reasons why Operational Group has designed the new OPTI-DRY 3.0 system.


He said: “More-and-more clients have raised the question: why are my dryers often running at maximum condition, using maximum supply and creating maximum exhaust air, for no valid reason? So by installing an OPTI-DRY 3.0 system, an optimum level will be set across the complete dryer and ventilation system, depending on your selected product.

“The monitoring system has a tailor-made HMI visual display allowing manufacturers to select the product they want. From this, the complete drying and air balance across the print stations/machine will be set automatically – from minimum efficient drying capacity with low coverages to maximum drying capacity with high coverages.

“The wide range of printed materials used by manufacturers also require different drying settings. These range from sensitive materials, such as tissue, which do not withstand high nozzle velocities to robust materials which require high nozzle velocities. With the OPTI-DRY 3.0 system the operator can select the perfect drying settings.”


With a combination of OPTI-DRY 3.0, an automatic LEL system and the required drying temperature, we can create maximum dryer energy savings.

Paul said: “By creating an optimal drying and air balance we can decrease the exhaust air to the abatement system and therefore create energy savings. By increasing the solvent load towards the abatement system, we can increase the heat recovery and, again, create significant energy savings.”


Product quality and production speeds often suffer due to poor set-up of drying systems. This incurs considerable costs in waste, lost time and energy. But our customers tell us they do not have the expertise to ensure optimum drying conditions day-in, day-out.

So Paul said: “The “OPTI-DRY 3.0” instrumentation system is designed to measure some key parameters which help the equipment operators to visualise what is happening within the process; see data that corresponds with optimum operating conditions; and have management and alarm functions to indicate when these conditions drift away from the ideal.

“Whilst appearing to be a simple process, drying can be very complex and difficult to set for the best results. This should help to minimize your drying related waste and reduce your environmental impact”


A combination between the OPTI DRY 3.0 and the EN1539:2015 will ensure that dryer is safe and meets PLd (SIL2) rated safety performance levels when VOCs are present.

OPTI DRY diagram

Paul said: “While creating a higher output and increasing your production speed, your dryer can be limited by the solvent concentrations (LEL). Operational Group has the possibility to increase the solvent concentrations from Range 1 to Range 2 and still show compliance with the EN1539:2015.

“Together with an independent company specialising in the assessment and management of risk, we have also developed ExSis, a certified solvent monitoring solution to ensure safety, potentially increase production speed and provide energy savings across your dryers and associated equipment. This will work in conjunction with OPTI DRY 3.0”


Operational can evaluate a system and identify how well the process is working, take remedial actions and achieve optimum conditions. Often there is a significant improvement in product quality and production speed.

Whilst Operational can provide periodic interventions to rebalance dryers to give the best performance on the day, we cannot be present continuously. So this has led us to develop this OPTI DRY 3.0 instrumentation and data system which constantly monitors the drying system every minute and help customers get the best out of their dryers. This information can then be remotely accessed by your staff and Operational, with the opportunity to diagnose and resolve problems quickly, potentially removing the need for a site visit.

Contact Operational Group to see how OPTI-DRY can help your business.