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Dixie Cup gets Production Boost from MeeFog System
Humidification for Industry
Dixie Consumer Products LLC, a Georgia-Pacific company, manufactures a range of paper goods including Dixie cups as well as paper plates, cups, napkins and other kitchen and bathroom products. Over the past decade, Georgia-Pacific has successfully implemented MeeFog humidification systems across multiple facilities to achieve precise humidity control, essential for high-quality production.
Benefits of MeeFog Technology for Humidity Control:
- Precise Humidity Management: Ensures distortion-free molding of paper products.
- Low Maintenance and Energy Efficiency: Reduces operating costs with minimal upkeep.
- Zone-Based Control: Allows independent operation across multiple production zones.
Challenge:
In 2016, Dixie Consumer Products opened a new 6,300-square-foot facility in Lexington, Kentucky, dedicated to the high-volume production of its popular Dixie Cups. The new factory called for precise control of relative humidity, particularly during the colder and drier months to maintain board moisture and prevent paper cups from distorting during the forming process.
As explained by Drew Lee, Engineer at Dixie Cup, the manufacturing process involves heating the polyethylene (poly) coating on the cups, which then forms an insulated “foam” texture. If the cups are too dry, they cannot form properly, resulting in production inefficiencies and potential product waste.
Solution:
To control the problem of distortion and improve humidity control, the relative humidity (RH) must be maintained at 45%. Dixie Cup installed a MeeFog humidification system for precise humidity control. The system’s ceiling-mounted fog nozzle lines are strategically distributed for optimal coverage and distribution.
“Mee Industries is a reputable vendor that has been used at numerous other facilities throughout our company.”
— Drew Lee, Engineer, Dixie Cup
The Installation and System Design
Already familiar with MeeFog systems’ effectiveness in previous facilities, Mee Industries was contacted once again to supply a MeeFog humidification system to help maintain high volume production. Dixie defined four areas of the plant for distinct operations, and each area was brought online separately. Using the Meefog model 2500 MFP rack outputs up to 5 GPM flow to four high pressure solenoids, and the onboard VFD uses only the power that’s needed for active zones.
- Efficient Water Flow: The 2500 MFP rack outputs up to 5 GPM, supplying high-pressure fog to four zones through independent solenoid valves.
- Variable Frequency Drive (VFD): The onboard VFD conserves energy by adjusting power output based on active zones, reducing operational costs.
- Zone Independence: Each of the four production zones in the plant can operate independently, allowing precise humidity control tailored to specific processes.
Cost-Benefit Analysis:
MeeFog systems have far lower energy costs than other types of humidification systems. For example, a MeeFog system designed for 1,000 lbs. of output per hour, operating 3,500 hours each year, will cost approximately $700 per year to operate, compared with $14,350 for compressed air atomizers and $128,800 for electric steam humidifiers. In addition, the MeeFog system cools the air as it humidifies, giving an added benefit of lower cooling costs.
Annual Operating Costs of Humidification Systems:
- MeeFog System: $700 per year
- Compressed Air Atomizers: $14,350 per year
- Electric Steam Humidifiers: $128,800 per year
Conclusion
The MeeFog system has proven invaluable in maintaining consistent humidity levels at Dixie’s new production facility, enabling distortion-free molding, minimizing energy costs, and allowing zone-specific control for optimal production efficiency.
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