By Greg Washburn and Joshua Belisle · Edited by Dana Gardner
Published August 4, 2024 · Reviewed by Greg Washburn · September 8, 2026
Summary
How fast does a central conveying and drying system pay back?
Payback depends on the losses a plant is already carrying, which a system survey or consultation can quantify. In one case study, a 57-machine molding plant added central drying and resin conveying for about $850,000 installed, saved an estimated $2,000,000 a year in energy, labor, downtime and wasted material, and paid back in about 5 months.
Investment Payback in Months – Not Years
You may think that the cost of a new or upgraded central system is difficult to justify but you won’t know for sure until you investigate the value of the losses you are suffering and the cost of the remedy.
It’s a lot like living with some body ache. It takes a qualified physician to diagnose your problem and the costs associated with curing – or not curing it. The remedy may be simple or complex. It may be costly or not – but you can only place a value on the investment when you realize your potential losses and savings.
Here are the facts:
- You don’t know how much you might be losing every month unless some kind of system survey is completed
- You may have a very specific area of loss that can be fixed with smart maintenance or a new vacuum pump etc.
- The areas of loss may be widespread – meaning that the monthly losses are threatening your existence as a profitable company
- A free consultation or a complete plant survey will place dollar values on your losses and offer a remedial action plan
Evaluating the Cost vs. Benefit
When we say, ‘Investment Payback in Months – Not Years’, we mean it, and we back up that statement with an example to show you how important it is to have a central systems professional evaluate conditions in your processing plant and offer solutions along with an analysis of your investment and payback. See payback worksheet below.
CASE STUDY – PAYBACK for 57 Machine Plant
Frequently Asked Questions
How do I find out what my resin handling system is costing me?
You won’t know how much you might be losing each month unless a system survey is completed. Losses can be specific, such as a problem fixed with smart maintenance or a new vacuum pump, or widespread across the plant. A consultation or full plant survey places values on those losses and produces a remedial action plan.
Where do the savings from a central system come from?
In the 57-machine case study, the estimated savings came from lower energy consumption, reduced labor, less machine downtime and less wasted material. The processor also reported a lower reject rate and higher production output after adding central drying and resin conveying.
Why should a professional evaluate my plant before a system upgrade?
Like a physician diagnosing an ache, a central systems professional has to identify the problem before the cost of fixing it, or not fixing it, is clear. The remedy may be simple or complex, costly or not. The evaluation covers plant conditions, recommended solutions, and an analysis of the investment and its payback.
About the Authors
Vice President of Operations, Novatec
Greg Washburn is Vice President of Operations at Novatec and has been with the company for more than three decades. He is involved in all phases of engineering design and product manufacturing, giving him a broad perspective on how resin drying and conveying equipment moves from engineering concept through production and into real-world processing environments. Greg holds a B.S. in Mechanical Engineering from the University of Maryland, Baltimore County (UMBC) and an MBA from Loyola University Maryland. His experience spans engineering, manufacturing and operations across Novatec’s material-handling technologies.
Technology Manager, Novatec
Joshua Belisle is Technology Manager at Novatec, where his work focuses on simulation and technology development for resin drying. He earned a B.S. in Mechanical Engineering with a minor in Engineering Business from the University of Virginia in 2023 and joined Novatec that same year. Joshua uses simulation tools to investigate previously difficult-to-measure aspects of the drying process, helping Novatec better understand airflow, heat transfer and other variables that influence resin-drying performance.
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