Reducing Scrap Through Humidity Control

Introduction

Even in the most well run facilities, a notable amount of inventory ends up being “dead” or “scrap.” The more dead inventory, the higher the handling cost spent counting, moving, and ultimately discarding product. It’s recommended that scrap rates stay below 5% – presenting a common challenge in many warehouses. Fortunately, much of this annual loss can be cut back by optimizing and monitoring humidity in your facility.

Excessively high or low humidity in a warehouse can lead to several problems. Increased risk of mold growth, corrosion of product, and rust all become potential risks. Surfaces ranging from ceilings to walls and floors can develop condensation, creating an environment conducive to pests and rodents. High humidity will also adversely affect stored products, even those in boxes and packaging.

This white paper will outline common problems facility managers face when it comes to humidity levels in their warehouses, as well as provide potential solutions to keep humidity at bay and eliminate unnecessary scrap.

Problem: Low vs. High Humidity

Maintaining optimal humidity levels in a warehouse is crucial for preserving quality and reducing scrap waste. Numerous products are sensitive to changes in moisture, especially when stored over long periods, and exposure can lead to unnecessary scap and losses. Most facilities are recommended to stay within 45 to 50% humidity year-round. [1][2] When humidity levels are out of range in either direction, warehouses quickly run into problems.

In environments with low humidity, materials lose flexibility. This leads to challenges in handling books and papers, shrinkage and detachment of bonded materials, and increased brittleness in paper, wood, and paint.

Conversely, high humidity can escalate the risk of mold growth and accelerate the acid hydrolysis process in paper and plastics. Accumulated moisture can also damage interior building structure and machinery.

Solution: Install High-volume Low-Speed (HVLS) Fans

High volume, low speed (HVLS) fans are particularly effective in keeping humidity in check. Unlike traditional ceiling fans, VividAir HVLS fans operate at a low speed, utilize fluid dynamics, have uniquely pitched blades, and provide consistent airflow and temperatures by generating a slow moving column of air. These fans naturally regulate humidity, moisture, and bacterial growth by design – all while being more energy efficient than traditional fans or HVAC alone.

Their large airflow capacity accelerates surface evaporation and lowers condensation risks. They also work efficiently in both summer and winter, mixing warm air at the ceiling with cool air on the floor to create an even temperature. HVLS fans can even make the perceived temperature in a room feel 8 to 9 degrees cooler, benefiting employees as well as minimizing potential scrap caused by human error. [3]

Because of their unique design, HVLS fans benefit both dry and humid climates when it comes to keeping humidity within the ideal range. Dry climates benefit from the evaporative cooling process, and humid climates see a clear reduction in mold, rust, and slippery surfaces.

Solution: Increased Ventilation

The World Health Organization also recommends increased ventilation as a method to control indoor humidity. [4] Ventilation plays a crucial role in removing or diluting pollutants, managing temperature, and maintaining a healthy humidity level in buildings. Luckily, there are many ways to improve ventilation in a facility.

The CDC recommends using filters with a high rating whenever possible and utilizing air purifiers that are the right size for your space. [5] Older systems should be upgraded to improve ventilation capacity. Changing filters regularly and keeping up with routine maintenance for all your air regulation components will increase ventilation, keep humidity levels where they need to be, and ensure scrap waste remains at a minimum.

Solution: Dehumidifiers

Integrating a mechanical dehumidifier can help if you’re dealing with high humidity levels contributing to scrap counts. An industrial dehumidifier can extract up to 160 pints of water from the air. Dehumidifiers are noisier than HVLS fans but can be a smart solution for very humid environments where condensation is already an issue in the building. It has the added benefit of curtailing airborne bacteria, commonly found in places where there are high concentrations of water vapor and airborne droplets.

Problem: Sweating Slab Syndrome

Sweating Slab Syndrome is a phenomenon that occurs when humidity causes moisture to collect on a surface, creating wet, dangerous, and slippery conditions. It affects workers, equipment, and products alike. Slips and falls are the most common cause of missed work, workers compensation claims, and ultimately loss of product. [6]

The leading cause of Sweating Slab Syndrome is when moist, warm, humid air meets cooler surfaces that are below the dew point temperature. This can happen through open doors in a loading dock, open windows, poor ventilation systems, or any entrance point not properly sealed. It’s most common in warmer regions but can happen anywhere where humid air during the day settles on floors that have cooled overnight.

Solution: Install HVLS fans

Solution: HVAC Moisture Control

A more expensive solution to Sweating Slab Syndrome is properly installed and maintained HVAC systems. Though less practical than HVLS fans for large warehouses, heating and air conditioning can control humidity levels and prevent the opportunity for moisture to pool on your floors. Adjusting the HVAC fan’s airflow and speed can also help – the slower the better. Reducing the CFM per ton will allow the evaporator coil to cool, reduce the fan’s airflow, and allow it to remove more moisture from the air.

Conclusion

Temperature and humidity control play a critical role in reducing scrap and product loss in industrial and commercial facilities. Using HVLS fans in conjunction with other humidity-reducing strategies is a safe, cost effective, and prudent way to tackle warehouse humidity. This approach not only reduces scrap, but makes employees more comfortable and productive, saves on energy costs, and promotes better indoor air quality.

Contact VividAir

VividAir is a high performance commercial HVLS fan manufacturer dedicated to the science of better air. Our patented designs include the Z-TechTM blade, a stepped symmetrical fan blade that dramatically reduces frictional resistance and drag while greatly increasing air displacement and thrust. The Z-Tech blade design provides an industry leading coverage area that’s 30% greater than the competition.

References

[1] Olli Seppänen and Jarek Kurnitski. WHO Guidelines for Indoor Air Quality: Dampness and Mould. National Library of Medicine. 2009. Available from: https://www.ncbi.nlm.nih.gov/books/NBK143947/

[2] Universsity of Texas Libraries. Temperature and Relative Humidity. 2021. Available from: https://guides.lib.utexas.edu/StorageCare/Temperature#:~:text=Acceptable%20temperatures%20for%20storing%20collections,radiators%2C%20windows%20and%20exterior%20walls

[3] MacroAir Technologies. Introduction to Specifying HVLS Fans. 2016. Available from: https://www.esmagazine.com/ext/resources/ES/White_Papers/Files/PDF/introduction-to-specifiying-hvls-fans-02021632.pdf

[4] World Health Organization. Coronavirus disease (COVID-19): Ventilation and air conditioning. 2021. Available from: https://www.who.int/news-room/questions-and-answers/item/coronavirus-disease-covid-19-ventilation-and-air-conditioning

[5] Centers for Disease Control and Prevention. Improving Ventilation in Buildings. 2023. Available from: https://www.cdc.gov/coronavirus/2019-ncov/prevent-getting-sick/improving-ventilation-in-buildings.html#:~:text=Bring%20more%20clean%20outdoor%20air,Even%20small%20openings%20can%20help.&text=Air%20cleaners%20

[6] National Floor Safety Institute. Slip & Fall Quick Facts. Available from: https://nfsi.org/nfsi-research/quick-facts/