How High-Pressure Fogging Improves Print Quality & Consistency

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Worker in blue uniform handling a stack of flat corrugated cardboard sheets on an industrial roller.

Maintain ideal humidity in printing environments

Industrial printing environments face ongoing challenges in maintaining the ideal 45% relative humidity, as humidity levels in North America and elsewhere can change rapidly—daily, seasonally, or annually.

When humidity levels change, paper products tend to:

Distort or warp
Have ink that dries unevenly, runs, or does not stick well
On corrugated paper, ink can soak in too deeply, which dulls colors and reduces vibrance.

The external climate is only one aspect. Operational factors also play a role. When bay doors are left open, sudden dips or surges in relative humidity can occur. Controlling humidity is critical to print quality and productivity while minimizing waste and rejects.

Benefits of MeeFog technology for printing

Printing precision, even on corrugated paper
Improved ink transfer, and press consistency
Annual savings of $100k+ compared to electric steam humidifiers

High-Pressure Fogging to Reduce Energy Costs While Maintaining Output

Industrial printing, corrugated paper, and other hybrid print environments can benefit from high-pressure fogging to accurately control humidity throughout the space. This is achieved through nozzle distribution that is tailored to the space and the needs of the printing equipment, and the use of the right kind of nozzles.

The facility can then maintain a given setpoint ideal for that production line, regardless of climatic or operational factors. The MeeFog humidification system uses a network of FogStat humidity sensors to ensure the desired humidity level is always delivered. The facility manager dictates the set point. Signals from the sensors regulate the flow of water to control humidity. The system can also be tied into building management systems.

A key factor in keeping a constant level of humidity in a printing environment is proper distribution of the humidification system throughout the facility. Compressed air, electric steam, and ultrasonic humidification systems typically provide humidification control in certain parts of the room. However, other areas become too dry or too humid. MeeFog addresses this problem by evenly spacing humidification nozzles throughout the room to deliver uniform humidity.

Real World Results

For example, a 6,300-square-foot printing facility specified that 45% relative humidity be maintained at all times to prevent paper distortion and ensure production targets were met by minimizing rejects. It suffered from major seasonal changes in humidity – very dry in winter and very humid in summer. They needed a way to keep the inside environment stable, no matter the weather outside.

MeeFog ceiling-mounted nozzle lines were strategically distributed for best coverage across four plant zones. The result was precise, evenly distributed humidity, improved product quality, and better press consistency and ink transfer. Tight humidity control was especially important during colder, drier winter months, helping the company maintain board moisture and avoid distortion.

The system consisted of a MeeFog 2500 MFP rack with a pump that outputs up to 5 GPM, supplying high-pressure fog to four zones at the facility through independent valves. An onboard Variable Frequency Drive (VFD) saves energy by adjusting power based on which zones are running, which lowers operating costs. Each of the four production zones in the plant can operate independently, so humidity can be controlled precisely for specific processes.

Stainless steel impaction-pin nozzle spraying a fine 20-micrometer mist for industrial humidification.

Achieve 45% relative humidity without wetting paper or equipment

The MeeFog system delivers filtered water at 1000 psi via a ceiling-mounted piping network. Fog nozzles convert water into fine mist for accurate humidity control. Each MeeFog impaction-pin nozzle is made from high-grade stainless steel. The standard nozzle features a 0.006 inch (150 micrometer) diameter orifice which produces billions of ultra-fine droplets per second. Droplet size averages are around 20 micrometers, or one tenth the diameter of a single strand of human hair. This system uses one horsepower of energy for every 500 pounds of water dispersed. This is roughly 8% of the energy usage of ultrasonic systems and about 5% of the energy required by compressed air systems.

Major cost and energy savings

Printing quality improved, and the number of rejects was substantially reduced. The biggest benefit, though, was the cost savings. A Meefog system designed for 1,000 lbs./hr output, running 3,500 hours/year, costs around $700 per year to operate. In comparison, compressed air atomizers cost $14,350 and electric steam humidifiers cost $128,800 for the same output. That’s up to 180 times less energy used for the same humidity.

Resources:

Learn more about how high pressure fog delivers significant energy savings for diverse industrial applications.

Industrial Humidification

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Jessica Olsen

Jessica specializes in translating high-level engineering concepts into actionable intelligence for the industrial technology sector. At Mee Industries, Jessica bridges the gap between engineering innovation and market engagement crafting content that simplifies the intricacies of gas turbine inlet air fogging and industrial cooling.