By Mark Haynie and Joshua Belisle · Edited by Dana Gardner
Published August 6, 2024 · Reviewed by Mark Haynie · September 7, 2026
Summary
How much energy does an old resin dryer waste?
Older resin dryers, especially desiccant bead dryers such as dual bed, twin tower, and carousel types, use far more energy than desiccant wheel dryers. Evaluating dryer energy could save an estimated $6,000 to $75,000 per year per dryer, based on $0.10/kWh, a 250°F drying temperature, and 8,400 hours a year. A paid-off dryer still costs money to run.
Old vs. Modern Drying Technology
Are you wasting energy and money on outdated and inefficient resin dryers? Evaluating your dryer energy could save you $6,000-$75,000 per year, per dryer. Maybe even more.
Many processors think once their dryer is paid for, it’s free – but nothing could be further from the truth. Old dryers cost processors untold millions in unnecessary utility costs. Could you save big by investing in a new dryer? In most cases, older dryers, just like old refrigerators and old cars, are energy hogs compared to dryers utilizing newer and more modern technology. This is not 100% true in every case but is certainly true when you compare older desiccant bead dryers to desiccant wheel dryers.
Estimated Dryer Energy Costs
Based on a single dryer, $ 0.10 /kwh and a drying temperature of 250˚ F. x 8,400 hrs./year.
Energy Tax Rebates
You may also be eligible for a tax rebates from your state or federal government or an energy rebate from your utility company which will save you even more! Even if you finance the purchase, there is still the potential to save some serious money every month.
Here’s how one company saved over $130,000 a year on one dryer:
Desiccant bead dryers (dual bed/twin tower and carousel types) use so much energy that replacement can be easily justified. Even if you keep the old desiccant bead dryer, adding the right gas-fired process heater can save thousands of dollars per month in energy costs.
- We were recently contacted by a company processing PET at a rate of 3,500 lb./hr.
- They were using an old dual bed dryer and running about 8,000 hr./yr.
- By switching to a 90% efficient gas-fired process heater and turning off the electric process heater, they will save over $130,000 per year.
Frequently Asked Questions
Is a paid-off resin dryer free to run?
No. Many processors assume a dryer costs nothing once it is paid for, but older dryers carry large ongoing utility costs. Like old refrigerators and old cars, older dryers are often energy hogs compared with newer designs. That is not true in every case, but it holds when older desiccant bead dryers are compared with desiccant wheel dryers.
Can a gas-fired process heater cut dual bed dryer energy costs?
Yes. Even if you keep an old desiccant bead dryer, adding the right gas-fired process heater can save thousands of dollars a month. In one example, a company processing PET at 3,500 lb/hr on an old dual bed dryer for about 8,000 hours a year projected savings of over $130,000 a year by switching to a 90% efficient gas-fired process heater.
Are there rebates for replacing an old resin dryer?
You may be eligible for tax rebates from your state or the federal government, or an energy rebate from your utility company, which adds to the savings from a more efficient dryer. Even if you finance the purchase, the monthly energy savings can still be significant.
About the Authors
Vice President of Moisture & Drying Technologies, Novatec
Mark Haynie is Vice President of Moisture & Drying Technologies at Novatec and has spent more than 40 years designing and installing resin drying systems in thousands of plastics plants. He leads Novatec’s drying technology group, including its work in moisture measurement and predictive drying, and serves as the technical reviewer for drying articles in the Novatec Knowledge Center.
Mark has authored numerous technical articles and white papers on resin drying and moisture control and answers processors’ drying questions through Novatec’s Ask the Expert program. He is a member of the Society of Plastics Engineers (SPE) and the American Institute of Chemical Engineers (AIChE), reflecting his involvement in both plastics processing and chemical engineering.
Technology Manager, Novatec
Joshua Belisle is Technology Manager at Novatec, with a focus on simulation and advanced engineering tools used to better understand the science of resin drying. Since joining Novatec in 2023, he has applied new simulation capabilities to investigate aspects of the drying process that were previously difficult to measure directly, helping turn complex process behavior into useful engineering insight.
Joshua earned a B.S. in Mechanical Engineering with a minor in Engineering Business from the University of Virginia in 2023. He is a member of the Society of Plastics Engineers (SPE) and the American Society of Mechanical Engineers (ASME), connecting his work in advanced simulation and engineering analysis with the broader plastics and mechanical engineering communities.
Related Articles
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Ask the Plastic Drying Expert
Author Profile:
Mark Haynie has designed and installed resin drying systems for more than 40 years, working in thousands of plastics plants across the industry. As Novatec’s Vice President of Moisture & Drying Technologies, he leads the company’s drying technology group, including its work on moisture measurement and predictive drying. He also serves as a technical reviewer for Novatec’s Drying Knowledge Center and has authored numerous technical articles and whitepapers on resin drying and moisture.
Mark earned a Bachelor of Science in Chemical Engineering from Virginia Tech.
Through Novatec’s Ask the Expert program, Mark regularly helps processors troubleshoot drying performance and resin-moisture challenges.