Moisture control in the packaging of dry foods

In the food industry, humidity affects the final quality of the product. For dry foods such as pasta, cereals, snacks or powdered ingredients, controlling the air in the packaging area ensures compliance with hygiene requirements and optimises operational costs.

An unsuitable microclimate during the final stage of production alters the texture, taste and shelf life of products, leading to losses that can be reduced through correctly sized technical solutions.

According to international estimates, approximately 30 per cent of food produced globally is lost or wasted in the supply chain, largely due to inadequate processing, packaging and storage conditions, including environmental factors such as uncontrolled temperature and humidity. This puts pressure on the profitability of food factories and the safety of the food supply chain.

Texco’s role in the packaging process

At Texco, we understand that a production manager must comply with contracts and food safety standards. Our approach focuses on:

• Diagnosing critical points. We identify areas on the packaging line where relative humidity fluctuates and affects the production flow.
• Equipment reliability. We use industry-recognised systems to maintain a constant level of humidity, reducing unplanned downtime.
• Compliance and documentation: We provide technical solutions with the necessary documentation to meet environmental standards and quality audits.

By balancing the microclimate, we maintain controlled conditions in the packaging area, where product quality is preserved right up to the point of sealing.

Why does air affect dry goods?

In the packaging area, the air interacts with the structure of the finished product. For foods with a low water content, the ambient environment affects the quality and net weight of the package.

The principle of equilibrium. Dry food products are hygroscopic. They absorb or release moisture until they reach equilibrium with the humidity level in the production hall. This phenomenon can lead to deviations from product standards if it is not monitored.

Risks of high humidity (>60% RH)

When relative humidity exceeds 60 per cent, products absorb water, leading to structural problems:

• Loss of texture. Biscuits, cereals or snacks alter their sensory properties. In practice, they become soggy rather than crisp and are therefore non-compliant.
• Dosing difficulties. Flour or powdered ingredients absorb water vapour and form lumps, blocking feeders and complicating the cleaning of machinery.
• Microbiological risks. Excessive moisture in sealed packaging can encourage the growth of mould during storage, compromising food safety.

Risks associated with low humidity (<35% RH)

An environment that is too dry affects the operation of automated packaging lines:

• Static electricity. Dry air generates electrostatic charges. The product behaves unpredictably (it emerges irregularly from the dosing unit or sticks to the pipework) and the packaging films fail to open or seal properly.
• Low efficiency: Operators reduce the line speed to compensate for errors, which lowers output and increases the cost per unit.

Our team analyses these thresholds to maintain humidity within an optimal range. The aim is to reduce the constant machine adjustments caused by imbalances in the workshop air.

Critical areas and practical scenarios

Managing a packaging line involves identifying areas where the microclimate affects the production flow. Based on Texco’s interventions, three common scenarios involving humidity imbalances that lead to operational losses have been identified.

Scenario A – the dosing and weighing area

The problem: blockages and dust. In low-humidity environments, products such as cereal flakes, short pasta or spices accumulate static electricity. The particles stick to the walls of the dosing units and the necks of the packaging machines, causing inaccurate dosing and stoppages for cleaning.
The solution? Depending on the size of the space and the energy or hygiene requirements, humidity stabilisation in the dosing area can be achieved either through high-pressure systems such as Condair HP for large halls, through Condair ML/MLP for compact, energy-efficient lines, or via Condair EL/RS electric steam generators in environments with strict hygiene requirements and precise humidity control. Result: reducing electrostatic charges allows the product to flow smoothly through the dosing unit. In continuous flow, optimising the environment can increase packaging speed by up to 15 per cent and reduce the time spent on manual interventions.

Scenario B – packaging and sealing area

Problem: returns and shelf life. If the air in the packaging area has high humidity, this enters the bag during sealing. For sensitive products such as coffee or snacks, residual moisture alters the texture and reduces shelf life, creating a risk of returns from retailers.

The solution? Depending on the volume of the packaging area, the level of precision required and hygiene requirements, humidity control can be achieved using Jumag process steam generators for rapid and stable control in large spaces, via electric steam systems integrated into the HVAC for specific production lines with strict compliance requirements, or via adsorption dehumidification solutions in situations where the main issue is constant excess ambient humidity.Result: air control at the packaging stage maintains stable conditions. This preserves the sensory properties of the food and ensures compliance with quality standards throughout the shelf life.

Scenario C – storage of the finished product

Problem: Packaging degradation. Excessive humidity in logistics areas affects the cellulose fibres in cardboard boxes. The packaging becomes soggy, pallet stacks become unstable and deformation occurs, which can lead to customers refusing delivery.
The solution? Depending on the warehouse temperature, the volume of the space and the stability of the ambient humidity, RH control can be achieved using Condair DA adsorption dehumidifiers for cold stores or areas with persistent condensation, Condair DC refrigeration systems in temperate areas with seasonal variations, or compact dehumidification units for specific logistics areas where rapid local control is required.Result: maintaining humidity below 50% preserves the integrity of secondary packaging. Logistics managers can ensure stock stability and reduce losses from handling damaged goods.

Selection matrix: which system is right for your process?

The choice of technology depends on the balance between the nature of the product, the volume of the space and specific hygiene requirements.

The table below provides a good starting point for identifying the right solution:

• For the production manager → this matrix aims to reduce the 5–15 per cent of rejects caused by uncontrolled air variations.
• For the technical director → the solutions are designed to be integrated into existing HVAC systems, ensuring predictable maintenance and compliance with current regulations.

Performance indicators (ROI)

Financial and operational indicators are used when assessing the modernisation of microclimate systems. Humidity control enables the return on investment to be monitored, with a payback period of 10–18 months in similar projects, through improvements in the following areas:

• Reduction in returns and product losses. Microclimate instability during packaging contributes to production losses estimated at between 5% and 15% across the industry.
• Quality protection. Maintaining humidity within stable parameters prevents changes to the sensory properties of dry foods, reducing the amount of non-compliant goods delivered to the customer.
• Ensuring shelf life. A controlled environment limits the residual moisture sealed within the packaging.
• Increasing productivity on packaging lines. Machine uptime is influenced by air quality.
• Smoother flow. Reducing electrostatic charges prevents blockages in dosing units, resulting in fewer stoppages for cleaning or unblocking.
• Line speed. Stable environmental conditions allow operation at rated speed, without frequent manual adjustments for humidity variations.
• Compliance and audit success. Documentation supports the process in regulated industries.
• International standards. Integrated solutions enable monitoring for compliance with HACCP, IFS or BRC.
• Data traceability. Data on microclimate parameters facilitates audits and confirms controlled conditions during packaging.

Our team can provide you with validated solutions that give technical managers and plant owners the data to justify the investment through measurable operational results.

How does Texco help you implement the right solution?

Implementing a microclimate control system in an operational food facility requires an approach that minimises operational risks. Our process is structured to provide technical certainty at every stage:

• Technical audit. Identifying the causes is not based on assumptions. We analyse the microclimate in the production hall and monitor humidity fluctuations over a 48-hour period to understand exactly how the air interacts with your products.
• Precise sizing. We calculate the required humidification or dehumidification by taking into account the actual volume of the warehouse, the air flow and the hygroscopic properties of the packaged foodstuffs, thereby avoiding undersizing or unnecessary consumption of resources.
• Installation tailored to production flow. We understand that time is money, which is why we plan the installation of Condair or Jumag systems so that production lines do not need to be halted, ensuring the continuity of deliveries.

Ask us for a technical microclimate audit with Texco! Within 48 hours, you’ll receive real-time data on humidity and airflows in your packaging and storage areas – the right basis for sizing the appropriate solution and reducing operational losses.

Frequently Asked Questions

In most dry food processing operations, the recommended range is 40–55% RH, adjusted according to the product’s hygroscopicity and the type of packaging.Usually between 2 and 7 days, depending on the size of the space and the complexity of integration into the HVAC system. Usually between 2 and 7 days, depending on the size of the space and the complexity of integration into the HVAC system.In most cases, no. Installation can be carried out in stages, without completely shutting down the production lines. A correctly sized system reduces indirect costs by eliminating scrap, downtime and frequent manual adjustments.Via digital sensors integrated into the BMS/HVAC system, with automatic data logging for auditing and traceability. Yes. Hygroscopic products can absorb or lose water, leading to variations in weight and commercial non-conformities. No. Air conditioning regulates temperature but cannot maintain RH precisely throughout the year. This leads to softening of texture, clumping in powders, microbiological risk and a shortened shelf life. Static electricity, inaccurate dosing, blockages and problems with film sealing.Through the traceability of microclimate data and the demonstration of controlled conditions during packaging and storage.