Humidity Control in Footwear Manufacturing - Case Study: DeAir Hands Over DeAir.RE-300 to Bitis

The Story of Humidity Control at Bitis

• 💡 Executive Summary
• 1. Challenges in the Vietnamese Footwear Industry
• 2. Case Study: DeAir Hands Over DeAir.RE-300 to Bitis
• 3. Achieved Results
• 4. Infographic: Before & After Comparison
• 5. Why Choose DeAir.RE Heat-Pump Dehumidifiers for Footwear?
• 6. Frequently Asked Questions (FAQ)

• Client: Bitis - A leading footwear brand in Vietnam.
• The Problem: High humidity (75-85%RH) severely impacted production processes and product quality.
• The Solution: DeAir delivered and installed DeAir.RE-300 Heat-Pump Dehumidifiers.
• The Results:
  • Stable humidity control at 45-55%RH.
  • Glue drying time reduced by 30-40%.
  • Defect rate dropped from 5-8% to <1%.
  • ROI: Full payback within 12-18 months.

⚠️ Glue Not Drying / Poor Adhesion

Shoe glue requires low humidity to dry properly and achieve optimal bonding. When humidity exceeds 60%RH:

• Glue drying time extends from 4-6 hours to 8-10 hours.
• Adhesion weakens, causing delamination and open toe gaps.
• Product defect rates spike to 5-8%.

🦠 Leather & Synthetic Materials Mold

Real leather and shoe lining fabrics have high moisture absorption rates:

• Leather absorbs moisture, leading to rapid mold growth.
• Fabrics and linings become damp, causing unpleasant odors.
• Product lifespan decreases, leading to customer complaints.

⏱️ Drying & Bonding Process Disruptions

High humidity disrupts the entire production line:

• Extended drying times reduce productivity by 15-20%.
• Raw material inventory piles up due to longer waiting times.
• Labor and electricity costs increase significantly.

📋 HUMIDITY REQUIREMENTS IN FOOTWEAR MANUFACTURING

❌ Before Installation

• Factory humidity: 75-85%RH (far too high for production).
• Glue drying issues: Waiting time increased from 4-6 hours to 8-10 hours.
• Shoe delamination rate: 5-8% (very high, causing massive waste).
• Mold growth: Appeared on leather and linings during the rainy season.
• Inventory backlog: Increased due to prolonged drying cycles.

✅ Bitis's Requirements

• Reduce humidity to 40-60%RH (the optimal range for footwear).
• Shorten drying/bonding time by at least 30%.
• Reduce the product defect rate to <1%.
• Save energy and align with eco-friendly practices.

• Maintained Humidity: 45-55%RH (Stable and fully compliant).
• Temperature: 24-27°C (Ideal for footwear production).
• Glue Drying Time: Reduced by 30-40% (from 8-10 hours down to 4-6 hours).
• Defect Rate: Dropped from 5-8% to <1%.

💰 ECONOMIC BENEFITS OF HUMIDITY CONTROL

📊 BEFORE & AFTER DEAIR.RE-300 INSTALLATION

Heat-Pump technology reuses the condensation heat to reheat the dehumidified air, saving 40% on electricity compared to conventional condensation dehumidifiers. This is the key factor helping Bitis drastically reduce monthly operational costs.

Q1: What is the ideal humidity for footwear manufacturing?

The ideal humidity depends on the specific production stage:

• Leather storage: 35%RH
• Glue application area: 40-50%RH (most optimal)
• Rubber production: 45-60%RH
• Finished goods warehouse: 40-50%RH

Generally, maintaining 40-60%RH is suitable for most footwear manufacturing processes.

Q2: What area size is the DeAir.RE-300 suitable for?

With a capacity of 300 kg/day and an airflow of 3,000 CMH, the DeAir.RE-300 is suitable for:

• Factory spaces with a volume of approximately 500-1,000 m³.
• Or an area of 150-300 m² (with a ceiling height of 3-3.5m).
• This varies based on the actual moisture load (number of workers, raw materials, initial humidity).

DeAir will conduct a survey and calculate the exact requirements before proposing the optimal number of units.

Q3: How long does installation and commissioning take?

The process typically takes 3-5 working days:

• Days 1-2: Survey, calculation, and equipment preparation.
• Days 3-4: Installation of the unit and ducting system.
• Day 5: Testing, calibration, and staff training.

DeAir commits to not disrupting the client's ongoing production during installation.

Q4: What is the operating cost of the DeAir.RE-300?

With a power consumption of 4.6 kW, running 10 hours/day:

• Electricity usage: 4.6 kW × 10 hours = 46 kWh/day.
• Electricity cost (assuming 3,000 VND/kWh): 46 × 3,000 = 138,000 VND/day.
• Monthly cost (26 working days): ~3.6 million VND/month.

However, thanks to Heat-Pump technology saving 40% on electricity, the actual cost is only about 2.2 million VND/month. Compared to the savings from reduced defective goods (200-300 million VND/year), this is a highly efficient investment.

Q5: Does DeAir provide solutions for large-scale factories?

Yes, DeAir offers a diverse range of solutions:

• High-capacity dehumidifiers: DeAir.RE-600, RE-900, RE-1200 (600-1,200 kg/day).
• Integrated Dezenno.MAX AHU systems: Airflow from 1,000 to 100,000 CMH.
• Customized solutions: Combining multiple units, integrating BMS/PLC for centralized monitoring.

DeAir has successfully deployed systems for major factories like Samsung, LG, VinGroup, and May Duc Giang.

Q6: How do you calculate the required number of machines?

DeAir uses professional software to calculate based on:

• The volume of the space to be treated (m³).
• Target humidity vs. current humidity.
• Moisture load from raw materials (leather, fabric, glue).
• Number of workers (each person releases 100-150g of moisture/hour).
• Required air exchange rates.

DeAir provides free survey and calculation services to ensure the right capacity and quantity are selected, preventing investment waste.

Humidity Control Solutions for Footwear - Efficient, Effective, Sustainable

Don't let high humidity reduce your product quality and increase your defect rates. DeAir is ready to partner with you, providing Heat-Pump dehumidifier solutions that save 40% on electricity and pay for themselves in just 12-18 months.

Is your footwear factory looking for an optimal humidity control solution?