{"id":7678,"date":"2025-08-15T09:00:00","date_gmt":"2025-08-15T08:00:00","guid":{"rendered":"https:\/\/uplastech.com\/plastic-drying-before-extrusion\/"},"modified":"2025-08-15T09:00:00","modified_gmt":"2025-08-15T08:00:00","slug":"plastic-drying-before-extrusion","status":"publish","type":"post","link":"https:\/\/uplastech.com\/de\/plastic-drying-before-extrusion\/","title":{"rendered":"Plastic Drying Before Extrusion: Hygroscopic vs Non-Hygroscopic Resins"},"content":{"rendered":"<style>\n.upl-blog{font-size:17px;line-height:1.78;color:#1f2937}\n.upl-blog p{margin:0 0 18px}\n.upl-blog h2{font-size:26px;line-height:1.3;color:#0b2b33;margin:46px 0 14px;font-weight:700;letter-spacing:-.015em}\n.upl-blog h3{font-size:19.5px;color:#0d3b47;margin:28px 0 10px;font-weight:700}\n.upl-blog ul,.upl-blog ol{margin:0 0 20px;padding-left:22px}\n.upl-blog li{margin:0 0 9px}\n.upl-blog figure{margin:0 0 34px}\n.upl-blog figure img{width:100%;height:auto;display:block;border-radius:10px}\n.upl-blog figcaption{font-size:13px;color:#6b7280;margin-top:10px;line-height:1.5}\n.upl-blog .toc{background:none;border:0;border-radius:0;padding:0;margin:0 0 34px}\n.upl-blog .toc .lwptoc{margin:0}\n.upl-blog .toc h4{margin:0 0 10px;font-size:13px;letter-spacing:.1em;text-transform:uppercase;color:#0d5563}\n.upl-blog .toc ol{margin:0;padding-left:18px;font-size:14.5px}\n.upl-blog .toc li{margin-bottom:6px}\n.upl-blog table{width:100%;border-collapse:collapse;font-size:14.5px;margin:0 0 10px}\n.upl-blog th{background:#0d3b47;color:#fff;text-align:left;padding:11px 13px;font-weight:600;font-size:13.5px;border:0}\n.upl-blog td{padding:11px 13px;border:0;border-bottom:1px solid #e8ebed;vertical-align:top}\n.upl-blog tbody tr:nth-child(even){background:#fafbfc}\n.upl-blog .tablecap{font-size:12.5px;color:#6b7280;margin:0 0 30px}\n.upl-blog .myth{background:#fff8ef;border:1px solid #f6ddbd;border-radius:8px;padding:16px 20px;margin:0 0 26px;font-size:15.5px}\n.upl-blog .myth b{color:#a85c10}\n.upl-blog .callout{background:#f2f8f9;border-radius:8px;padding:18px 22px;margin:0 0 26px;font-size:15.5px;border-left:3px solid #14707f}\n.upl-blog .faq h3{border-top:1px solid #eceff1;padding-top:22px;margin-top:0;font-size:18px}\n.upl-blog .faq h3:first-of-type{border-top:0;padding-top:0}\n.upl-blog .cta{background:linear-gradient(135deg,#0b2b33,#0d5563);color:#fff;border-radius:12px;padding:34px;margin:48px 0 30px}\n.upl-blog .cta h2,.upl-blog .cta .cta-h{color:#fff;margin:0 0 10px;font-size:24px;font-weight:700;line-height:1.3}\n.upl-blog .cta p{color:#c9dee3;margin:0 0 20px;font-size:16px}\n.upl-blog .btn{display:inline-block;background:#e07a1f;color:#fff;text-decoration:none;font-weight:700;padding:13px 26px;border-radius:8px;font-size:15.5px}\n.upl-blog .rel{border-top:1px solid #e8ebed;margin-top:40px;padding-top:26px}\n.upl-blog .rel h4{font-size:13px;letter-spacing:.1em;text-transform:uppercase;color:#6b7280;margin:0 0 14px}\n.upl-blog .rel ul{list-style:none;padding:0;margin:0}\n.upl-blog .rel li{padding:11px 0;border-bottom:1px dashed #e8ebed}\n.upl-blog .rel a{text-decoration:none;font-weight:600;font-size:15.5px}\n@media(max-width:640px){.upl-blog h2{font-size:22px}.upl-blog table{font-size:13px}.upl-blog .cta{padding:24px}}\n\/* \u5355\u7bc7\u9875\u9690\u85cf WhatsApp \u81ea\u52a8\u5c55\u5f00\u7684\u95ee\u5019\u5361\uff0c\u53ea\u4fdd\u7559\u5706\u5f62\u6c14\u6ce1\uff0c\u907f\u514d\u906e\u6321\u4fa7\u680f\u8be2\u76d8\u63d0\u4ea4\u6309\u94ae *\/\nbody.single-post .ht_ctc_chat_greetings_box{display:none !important}\n<\/style>\n<div class=\"upl-blog\">\n<figure>\n<img fetchpriority=\"high\" decoding=\"async\" src=\"https:\/\/uplastech.com\/wp-content\/uploads\/2026\/10\/plastic-drying-before-extrusion.jpg\" alt=\"Chart showing moisture content falling over time for different resins at their recommended drying temperatures\" width=\"1536\" height=\"909\"><figcaption>Every hygroscopic resin has a drying curve. The shape matters more than the endpoint \u2014 the last 20% of moisture takes as long as the first 80%.<\/figcaption><\/figure>\n<div class=\"toc\"><\/div>\n<h2 id=\"why\">Moisture is the most expensive defect you cannot see<\/h2>\n<p>A dryer costs a few thousand dollars and runs on a few kilowatts. A batch of hydrolysed polycarbonate costs a shift of production, a customer complaint and sometimes a mould. The ratio is so lopsided that drying should be the least controversial part of any extrusion line \u2014 and yet it is the step most often set to a number someone remembered from a previous job.<\/p>\n<p>The reason moisture is dangerous is that it attacks the polymer chemically, not just physically. In polycondensation polymers \u2014 PC, PA, PET, PBT, POM \u2014 water at melt temperature breaks the polymer chain. The reaction is called hydrolysis, and it is not reversible. The molecular weight drops, and with it the impact strength and elongation.<\/p>\n<div class=\"callout\">\n<p><strong>The signature:<\/strong> hydrolysis shows up as a drop in impact strength and elongation while tensile strength barely changes. Visually it appears as silver streaking, bubbles, or a dull surface. By the time you see silver streaks, the material has already lost a significant part of its toughness.<\/p>\n<\/div>\n<h2 id=\"hygroscopic\">Hygroscopic versus non-hygroscopic<\/h2>\n<p>The first question is whether the resin needs drying at all. It depends on how it interacts with water.<\/p>\n<table>\n<thead>\n<tr>\n<th>Behaviour<\/th>\n<th>Harze<\/th>\n<th>Mechanism<\/th>\n<th>Needs drying?<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>Non-hygroscopic<\/td>\n<td>PE, PP, PS, PVC (rigid)<\/td>\n<td>Water sits on the surface only<\/td>\n<td>No, but avoid condensation<\/td>\n<\/tr>\n<tr>\n<td>Slightly hygroscopic<\/td>\n<td>ABS, PMMA, PC\/ABS<\/td>\n<td>Surface absorption, slow diffusion<\/td>\n<td>Yes, 2\u20134 h<\/td>\n<\/tr>\n<tr>\n<td>Hygroscopic<\/td>\n<td>PA, PC, PBT, PET, POM<\/td>\n<td>Water diffuses into the pellet and bonds<\/td>\n<td>Yes, 3\u20136 h at 100\u2013120 \u00b0C<\/td>\n<\/tr>\n<tr>\n<td>Very hygroscopic<\/td>\n<td>PA6, PA66, TPU, EVOH<\/td>\n<td>Rapid uptake, strong bonding<\/td>\n<td>Yes, 4\u20138 h, sealed handling<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p class=\"tablecap\">Table 1 \u2014 Resin classes by moisture behaviour. The non-hygroscopic group still needs care: a cold pellet entering a warm hopper condenses water on its surface.<\/p>\n<p>The non-hygroscopic group is not entirely safe. Pellets stored in a cold warehouse and moved into a warm plant will condense moisture on their surface, and that surface water becomes steam at the die. It is not hydrolysis, but it produces the same bubbles and streaks. Letting bags reach room temperature before opening solves it.<\/p>\n<h2 id=\"curve\">Reading a drying curve<\/h2>\n<p>A drying curve plots moisture content against time at a fixed temperature and dew point. It has a characteristic shape: a fast initial drop as surface water leaves, then a slow approach to equilibrium as water diffuses out of the pellet core.<\/p>\n<table>\n<thead>\n<tr>\n<th>Stage<\/th>\n<th>What is happening<\/th>\n<th>Share of time<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>Surface moisture removal<\/td>\n<td>Free water evaporates from the pellet surface<\/td>\n<td>10 \u2013 20%<\/td>\n<\/tr>\n<tr>\n<td>Diffusion-controlled drying<\/td>\n<td>Water migrates from the core to the surface and evaporates<\/td>\n<td>60 \u2013 70%<\/td>\n<\/tr>\n<tr>\n<td>Approach to equilibrium<\/td>\n<td>Drying rate balances the moisture in the drying air<\/td>\n<td>20 \u2013 30%<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p class=\"tablecap\">Table 2 \u2014 The three stages of drying. The last stage is why drying time is not linear: doubling the time does not halve the moisture.<\/p>\n<p>The equilibrium point is set by the dew point of the drying air, not by the temperature. This is the single most misunderstood fact about dryers. A desiccant dryer running at \u221240 \u00b0C dew point can pull a resin down to 0.02% moisture; a hot-air dryer at +10 \u00b0C dew point will stall at 0.15% no matter how long it runs.<\/p>\n<h2 id=\"dryers\">Dryer types and what each achieves<\/h2>\n<table>\n<thead>\n<tr>\n<th>Typ<\/th>\n<th>Achievable dew point<\/th>\n<th>Achievable moisture<\/th>\n<th>Kosten<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>Hot air (no desiccant)<\/td>\n<td>+5 to +15 \u00b0C<\/td>\n<td>0.10 \u2013 0.20%<\/td>\n<td>Lowest<\/td>\n<\/tr>\n<tr>\n<td>Desiccant, twin tower<\/td>\n<td>\u221220 to \u221240 \u00b0C<\/td>\n<td>0.02 \u2013 0.05%<\/td>\n<td>Mittel<\/td>\n<\/tr>\n<tr>\n<td>Desiccant, compressed air<\/td>\n<td>\u221240 to \u221260 \u00b0C<\/td>\n<td>0.01 \u2013 0.03%<\/td>\n<td>High (air cost)<\/td>\n<\/tr>\n<tr>\n<td>Vacuum dryer<\/td>\n<td>\u2014<\/td>\n<td>0.01 \u2013 0.02%<\/td>\n<td>Highest<\/td>\n<\/tr>\n<tr>\n<td>Infrared \/ rotary drum<\/td>\n<td>\u2014<\/td>\n<td>0.02 \u2013 0.05%<\/td>\n<td>Hoch<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p class=\"tablecap\">Table 3 \u2014 Dryer types. The dew point is the number to ask for, not the temperature. A dryer set to 120 \u00b0C with a wet desiccant bed is worse than useless.<\/p>\n<p>Vacuum drying is different in principle: it lowers the boiling point of water so the resin dries at 80\u2013100 \u00b0C in a fraction of the time. It is used where residence time matters, such as in-line drying before a medical extrusion, and it costs accordingly.<\/p>\n<h2 id=\"settings\">Settings by resin<\/h2>\n<table>\n<thead>\n<tr>\n<th>Resin<\/th>\n<th>Temperature (\u00b0C)<\/th>\n<th>Time (h)<\/th>\n<th>Target moisture (%)<\/th>\n<th>Anmerkungen<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>ABS<\/td>\n<td>80<\/td>\n<td>2 \u2013 3<\/td>\n<td>< 0.10<\/td>\n<td>Over-drying causes colour shift<\/td>\n<\/tr>\n<tr>\n<td>PMMA<\/td>\n<td>80<\/td>\n<td>3 \u2013 4<\/td>\n<td>< 0.05<\/td>\n<td>Bubbles and haze if wet<\/td>\n<\/tr>\n<tr>\n<td>PC<\/td>\n<td>120<\/td>\n<td>3 \u2013 4<\/td>\n<td>< 0.02<\/td>\n<td>Hydrolyses readily; strict<\/td>\n<\/tr>\n<tr>\n<td>PA6 \/ PA66<\/td>\n<td>80 \u2013 100<\/td>\n<td>4 \u2013 6<\/td>\n<td>< 0.10<\/td>\n<td>Reabsorbs in minutes when exposed<\/td>\n<\/tr>\n<tr>\n<td>PBT<\/td>\n<td>120<\/td>\n<td>3 \u2013 4<\/td>\n<td>< 0.03<\/td>\n<td>Hydrolysis drops IV fast<\/td>\n<\/tr>\n<tr>\n<td>PET<\/td>\n<td>140 \u2013 160<\/td>\n<td>4 \u2013 6<\/td>\n<td>< 0.02<\/td>\n<td>Also needs crystallisation before drying<\/td>\n<\/tr>\n<tr>\n<td>POM<\/td>\n<td>80 \u2013 90<\/td>\n<td>2 \u2013 3<\/td>\n<td>< 0.10<\/td>\n<td>Overheating releases formaldehyde<\/td>\n<\/tr>\n<tr>\n<td>TPU<\/td>\n<td>80 \u2013 100<\/td>\n<td>2 \u2013 4<\/td>\n<td>< 0.03<\/td>\n<td>Very hygroscopic; keep sealed<\/td>\n<\/tr>\n<tr>\n<td>EVOH<\/td>\n<td>60 \u2013 80<\/td>\n<td>2 \u2013 4<\/td>\n<td>< 0.10<\/td>\n<td>Low temperature; degrades hot<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p class=\"tablecap\">Table 4 \u2014 Drying schedules. PC and PET are the strictest; ABS and PMMA are more forgiving but will still show defects if wet.<\/p>\n<p>PET has an extra step: it must be crystallised before drying, or the amorphous pellets soften and stick together in the dryer. Crystallisation is a 10-minute agitation at 150\u2013170 \u00b0C before the drying phase. Skipping it produces a solid lump in the hopper.<\/p>\n<h2 id=\"verify\">Verifying that drying worked<\/h2>\n<p>Setting the dryer is not the same as drying the resin. Three ways to check, in increasing order of usefulness.<\/p>\n<table>\n<thead>\n<tr>\n<th>Methode<\/th>\n<th>What it measures<\/th>\n<th>Limitation<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>Dryer display<\/td>\n<td>Set point and return air temperature<\/td>\n<td>Tells you nothing about the resin<\/td>\n<\/tr>\n<tr>\n<td>Dew point meter<\/td>\n<td>Drying air quality<\/td>\n<td>Air can be dry and resin still wet<\/td>\n<\/tr>\n<tr>\n<td>Moisture analyser<\/td>\n<td>Actual resin moisture<\/td>\n<td>Needs equipment and time<\/td>\n<\/tr>\n<tr>\n<td>Loss-in-weight test<\/td>\n<td>Moisture by weight difference<\/td>\n<td>Slow but simple<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p class=\"tablecap\">Table 5 \u2014 Verification methods. Only the last two tell you about the resin; the first two tell you about the machine.<\/p>\n<p>The cheapest practical check is the weight-loss test: weigh a sample, dry it at the recommended schedule in a laboratory oven, weigh again, and calculate the moisture as a percentage of the original weight. It takes a few hours and needs only a balance and an oven, and it will tell you immediately whether the production dryer is doing its job.<\/p>\n<h2 id=\"mistakes\">The mistakes that cost the most<\/h2>\n<table>\n<thead>\n<tr>\n<th>Mistake<\/th>\n<th>Consequence<\/th>\n<th>Fix<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>Drying by time, not by dew point<\/td>\n<td>Resin stalls above target moisture<\/td>\n<td>Check desiccant, measure dew point<\/td>\n<\/tr>\n<tr>\n<td>Overloading the dryer<\/td>\n<td>Insufficient airflow, uneven drying<\/td>\n<td>Respect rated capacity; 60\u201370% is safer<\/td>\n<\/tr>\n<tr>\n<td>Wet desiccant<\/td>\n<td>Dryer becomes a humidifier<\/td>\n<td>Regeneration cycle; replace desiccant yearly<\/td>\n<\/tr>\n<tr>\n<td>Drying then exposing to air<\/td>\n<td>PA reabsorbs moisture in 10\u201320 min<\/td>\n<td>Sealed conveying, dry hopper on the machine<\/td>\n<\/tr>\n<tr>\n<td>Too hot<\/td>\n<td>Colour shift, sticking, degradation<\/td>\n<td>Stay at the resin's recommended temperature<\/td>\n<\/tr>\n<tr>\n<td>Not drying regrind longer<\/td>\n<td>Regrind has more surface area, holds more water<\/td>\n<td>Add 30\u201350% to drying time<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p class=\"tablecap\">Table 6 \u2014 The six drying mistakes that cause most hydrolysis failures. The desiccant one is the most common and the least visible.<\/p>\n<p>The wet-desiccant failure is worth spelling out because it inverts the process. A saturated desiccant bed releases moisture into the drying air, so the dryer actively adds water to the resin while the temperature display reads perfectly normal. The resin comes out wetter than it went in. The only way to catch it is to measure the dew point of the supply air, which almost nobody does.<\/p>\n<div class=\"faq\">\n<h3>Do I need to dry PP or PE?<\/h3>\n<p>Generally no. Polyolefins are non-hygroscopic and water only sits on the surface. The exception is condensation: if cold pellets are moved into a warm humid plant, water condenses on them. Let bags reach room temperature before opening, and keep the hopper covered.<\/p>\n<h3>Why is dew point more important than temperature?<\/h3>\n<p>Because the equilibrium moisture a resin can reach is set by the humidity of the drying air, not its temperature. A desiccant dryer at \u221240 \u00b0C dew point pulls PC down to 0.02%; a hot-air dryer at +10 \u00b0C dew point stalls at 0.15% no matter how long it runs.<\/p>\n<h3>How do I know if my desiccant is spent?<\/h3>\n<p>Measure the dew point of the supply air. If it rises above \u221220 \u00b0C on a twin-tower dryer that should be running at \u221240 \u00b0C, the bed is not regenerating properly. Common causes are a failed regeneration heater, a stuck valve, or desiccant that has degraded and needs replacing.<\/p>\n<h3>Can I over-dry a resin?<\/h3>\n<p>Yes. Over-drying wastes energy and can cause problems: ABS and PMMA can shift colour, PA becomes brittle and generates dust, and some resins oxidise at elevated temperature. Dry to the specification, not beyond it.<\/p>\n<h3>How long can dried resin sit before it reabsorbs moisture?<\/h3>\n<p>For PA and TPU, minutes to tens of minutes in open air. For PC and PBT, hours. The practical answer is to keep dried resin in a sealed hopper on the machine and never leave it in an open container.<\/p>\n<h3>Does regrind need longer drying?<\/h3>\n<p>Yes, 30\u201350% longer. Regrind flake has roughly ten times the surface area of pellets, so it absorbs moisture faster and holds it more tenaciously. If the regrind is also older or has been stored in a humid area, extend further.<\/p>\n<h3>What happens if I extrude wet polycarbonate?<\/h3>\n<p>Hydrolysis. Water at 300 \u00b0C breaks the carbonate linkage, molecular weight drops, and impact strength falls sharply. Visually you get silver streaks and bubbles; mechanically the part becomes brittle. The damage is permanent and cannot be reversed by re-drying.<\/p>\n<h3>Is vacuum drying worth the cost?<\/h3>\n<p>Only when residence time is critical. A vacuum dryer can dry PC in 20\u201330 minutes instead of 4 hours, which matters for in-line processes and for short runs where a full hopper of dried material would be wasted. For normal production, a desiccant dryer is sufficient.<\/p>\n<\/div>\n<div class=\"cta\">\n<p class=\"cta-h\">Seeing silver streaks or brittle parts?<\/p>\n<p>Tell us the resin, the dryer type and set points, and the defect you are seeing. We will tell you whether it is moisture, and what dew point and residence time the material actually needs.<\/p>\n<p><a class=\"btn\" href=\"https:\/\/uplastech.com\/de\/losungen-fur-die-kunststoffextrusion\/\">Talk to an extrusion engineer<\/a>\n<\/div>\n<div class=\"rel\">\n<h4>Continue reading<\/h4>\n<ul>\n<li><a href=\"https:\/\/uplastech.com\/de\/regrind-recycled-content-extrusion\/\">Regrind and Recycled Content in Extrusion: Ratios and Property Loss<\/a><\/li>\n<li><a href=\"https:\/\/uplastech.com\/de\/pc-injection-molding-guide\/\">PC Injection Molding: Drying, Melt Temperature and Stress Cracking<\/a><\/li>\n<li><a href=\"https:\/\/uplastech.com\/de\/nylon-pa-injection-molding-guide\/\">Nylon (PA6 \/ PA66) Injection Molding: Moisture and Dimensions<\/a><\/li>\n<li><a href=\"https:\/\/uplastech.com\/de\/fehler-in-der-kunststoffextrusion\/\">Plastic Extrusion Defects: 12 Problems, Causes and Fixes<\/a><\/li>\n<li><a href=\"https:\/\/uplastech.com\/de\/melt-pump-screen-changer-pressure-stability\/\">Melt Pump and Screen Changer: Why Pressure Stability Beats Temperature<\/a><\/li>\n<\/ul>\n<\/div>\n<\/div>","protected":false},"excerpt":{"rendered":"<p>A dryer set to the wrong dew point is worse than no dryer. How to read a drying curve, what desiccant and hot air actually achieve, and which resins need it.<\/p>","protected":false},"author":1,"featured_media":7671,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_seopress_titles_title":"Plastic Drying Before Extrusion: Hygroscopic vs Non-Hygrosco","_seopress_titles_desc":"A dryer set to the wrong dew point is worse than no dryer. 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