As cable extrusion advances towards higher speeds, greater automation and increasingly demanding polymer applications, controlling moisture is emerging as an important factor in maintaining process consistency and product quality. In this authored article, shared with Wire & Cable India, Dr. Vijay Chaudhry, Chief Executive Officer, Bry-Air (Asia) Pvt. Ltd., explores how precise moisture and dew-point control can support stable extrusion, while highlighting evolving drying technologies and the potential of waterless drying for moisture-sensitive cable compounds.
Wire and cable extrusion is becoming faster, more automated and increasingly dependent on advanced polymers. As manufacturers move toward applications such as EVs, fibre optics and high-performance cables, process consistency is becoming just as important as line speed.
Moisture control is one part of this equation that deserves closer attention.
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Cable manufacturers already use dehumidification for hygroscopic materials such as PBT and PA/nylon. A dehumidifying dryer is suggested for FRLS and ZHFR cables to remove moisture from the compound granules before processing. However, the focus is often on achieving the required resin condition rather than treating moisture and dew point as active process-control parameters. This matters because moisture-sensitive polymers can experience hydrolysis or processing defects when inadequately dried. Consistent low-dew-point air helps create repeatable drying conditions before the material enters the extrusion process.
The drying technology itself is also evolving. Conventional desiccant systems remain widely used, while manufacturers are increasingly looking at energy efficiency, reduced water consumption and simpler auxiliary systems. This is where waterless drying offers an interesting approach. Bry-Air’s Wonder Dryer™ uses desiccant-based dehumidification without requiring a chilled-water circuit for the drying process. By eliminating the need for associated chiller, cooling-water and condensate infrastructure, the approach can help simplify the drying system while maintaining controlled dry-air conditions for moisture-sensitive plastics.
Also Read: Wire & Cable India Emagazine Sep-Oct Issue 2026
As cable extrusion moves toward higher speeds and tighter quality requirements, moisture control should not be viewed simply as a pre-processing step. It is becoming part of the broader effort to achieve stable processing, consistent quality and more efficient manufacturing.
