When selecting a drying solution for your production line, the choice between Secomak’s DryGuide and the newly launched DryGuide Essential can feel overwhelming. While both machines deliver Secomak’s proven drying technology, they serve different operational needs. The DryGuide Essential is designed to provide an economical option without sacrificing the core drying performance Secomak is known for. This article will explore the strengths of both machines, helping you make an informed decision based on your production speed, budget, and specific drying requirements.
Key Feature Comparisons
The original DryGuide has been a market leader since its launch in 2015, and with nearly 1,000 units sold, it continues to be the go-to for high-speed, flexible production lines. It’s perfect for large beverage and food operations that require versatility in drying a variety of containers, including cans, bottles, jars, and aerosols. In contrast, the DryGuide Essential has been developed for lower-volume production lines, offering the same high-performance drying technology at a reduced capacity and cost, making it an ideal choice for smaller producers or those with simpler needs.
Performance & Capacity:
The original DryGuide can handle up to 125,000 cans or 80,000 bottles per hour, making it ideal for high-speed production lines that require the fastest drying speeds. On the other hand, the DryGuide Essential is designed for slower production speeds, handling up to 50,000 cans or 30,000 bottles per hour. While the Essential may have a lower throughput, it delivers energy-efficient and consistent drying for businesses that don’t need the speed of the original DryGuide.
Size & Space:
Both machines share the same compact width, but the DryGuide Essential is 20% shorter, making it easier to fit into space-constrained production lines.
The Essential’s top-mounted blower design also enhances its compactness, ensuring effortless installation in both new and existing production environments.
Blower Technology
One of the significant differences between the two machines is the blower technology. The original DryGuide uses a 15kW belt-driven centrifugal fan. This fan offers robust performance and has proven reliability in high-speed production lines. However, the new DryGuide Essential employs an 11kW direct-drive blower, which removes the need for regular belt maintenance, offering a virtually maintenance-free solution that still delivers excellent energy efficiency.
Ease of Use & Maintenance
Both machines are designed with ease of use in mind. The DryGuide features Secomak’s iconic gull-wing doors for easy access to the machine, ensuring quick changes between formats with no tools required. The DryGuide Essential maintains this ease of access but incorporates a more streamlined, ergonomic sliding door design, ideal for operators in smaller production environments. While the original DryGuide’s belt-driven fan may require more frequent maintenance, its longer lifespan and robust design make it a solid investment for larger facilities. The Essential, with its direct-drive fan, reduces the frequency of required maintenance but may require more significant overhauls over time.
Energy Efficiency & Controls
Both machines feature advanced control systems. The DryGuide operates utilising a PLC that can be customised, allowing users seamlessly integrate it with their existing systems. On the other hand, the DryGuide Essential is fitted with Secomak’s AirMinder controls, a simpler yet effective solution that automates energy savings by running the blower only when containers are present. This makes the Essential particularly energy-efficient, especially for smaller production lines that may not require the complexity of full PLC controls
Applications & Use Cases
Who Should Choose the DryGuide?
If your production line runs at high speeds (above 50,000 cans or 30,000 bottles per hour), the original DryGuide is the best choice. It excels in high-volume environments and offers greater flexibility for regularly changing container formats. Additionally, if your facility has stringent regulatory or control requirements, the DryGuide’s fully customisable PLC and blower controls are unmatched.
Who Should Choose the DryGuide Essential?
For operations running below 50,000 cans or 30,000 bottles per hour, the DryGuide Essential provides an affordable, efficient solution. Its compact design and lower maintenance requirements make it ideal for smaller producers or facilities where space is at a premium. The Essential’s simplicity in both control and maintenance allows businesses to experience the benefits of Secomak’s drying technology without the need for extensive line integration and future maintenance requirements.
Price and Value Comparison
Cost is always a significant factor in the decision-making process, especially when selecting machinery for your production line. The DryGuide Essential was designed to provide high-performance drying technology at a more economic price, at approximately 35% lower than the original DryGuide. This price reduction makes the Essential particularly attractive for smaller-scale operations or businesses that don’t require the maximum capacity or modular customisations of the original DryGuide.
However, this doesn’t result in a compromise in performance. The DryGuide Essential offers a version of Secomak’s tried & tested DryGuide technology, ensuring exceptional drying results with its equally efficient 11kW direct-drive centrifugal fan. When compared with alternative drying methods such as compressed air systems, it will result in lower long-term energy costs, providing less frequent maintenance, making it an attractive long-term investment.
For businesses requiring higher production speeds or more complex customisations, the original DryGuide provides added value with its powerful 15kW blower and fully customisable controls, offering greater flexibility for a wide range of container formats. In terms of maintenance, the belt-driven blower in the DryGuide, while more powerful, requires periodic maintenance, whereas the direct-drive fan of the Essential is virtually maintenance-free. Both machines are engineered for long-term reliability, ensuring a good return on investment, but the right choice depends on your specific needs.
Comparison Chart
| Feature | DryGuide | DryGuide Essential |
| Variations: | Endless applications with customisable options for all drying applications | Offered in single variations and not modular, designed for fixed applications. |
| Speed Capacity: | Bottles: Application dependent up to 80,000 bottles per hour (multiple modules joined together)
Cans: Application dependent up to 125,000 cans per hour (multiple modules joined together). |
Bottles: Application dependent up to 30,000 bottles per hour
Cans: Application dependent up to 50,000 cans per hour |
| Size: | L = 1500mm
W = 800mm H = Customisable
|
L = 1200mm
W = 800mm H = Customisable |
| Drying Fixtures: | Original DryGuide technology.
Featuring a double DryGuide pass to dry bottles of any height. |
New DryGuide technology with a drying pass that is height adjustable, but limited on bottle height – 300mm. |
| Blower: | Secomak 15kW 587 Turbo – belt driven centrifugal fan mounted internally at low level for ease of maintenance | Secomak 11kW 587 Turbo – Directly driven centrifugal fan mounted at high level internally |
| Controls: | Options are endless utilising our EcoPack control panel. Siemens Logo PLC & Danfoss VFD as standard but can be changed to match customers preferred. Additional safety options available as an option including E-Stop. | Available in a single configuration utilising our VFD controlled AirMinder. |
| Maintenance: | Minimal requirements | Minimal requirements |
| Adjustments: | Both machines require no change parts or tools when making adjustment between formats. | |
| Hygiene: | All parts manufactured from stainless steel or food grade plastics. Integrated drip tray with single hose point. | |
| Doors: | Gull wing style stainless steel lined doors suitable for hose down cleaning. | Sliding door mechanism with transparent style Perspex doors. |
| Installation: | Suitable for new & existing production lines. | Suitable for new & existing production lines. |
| Compliance: | UKCA, CE, UL, CSA as standard | UKCA, CE, as standard
UL, CSA as an option |
Maintenance & Lifecycle Costs: Planning for the Long Term
When investing in drying equipment, it’s essential to consider not just the upfront cost but the Total Cost of Ownership (TCO) over the machine’s lifecycle. Maintenance requirements, energy consumption, and expected lifespan can significantly impact the long-term value of your investment. Below, we discuss the differences in maintenance schedules, costs, and expected lifespans for the DryGuide and DryGuide Essential, helping you make an informed decision based on long-term operational costs.
Maintenance Differences
- DryGuide:
The DryGuide features a 15kW belt-driven centrifugal fan, which, while powerful, requires periodic maintenance. Over time, the belts will need replacing to ensure the fan continues to operate efficiently. However, this system has a longer lifespan, offering higher performance for high-speed production environments. Typical maintenance intervals include regular belt inspections and replacements every 2–3 years, depending on usage, with minor service checks in between. - DryGuide Essential:
The DryGuide Essential employs a direct-drive 11kW centrifugal fan, eliminating the need for belts and thus significantly reducing maintenance costs. This design is virtually maintenance-free, requiring only periodic checks to ensure optimal performance. Although the direct-drive system may need a more significant overhaul after 7–10 years, its lower maintenance requirements make it an attractive option for businesses prioritising ease of use.
Total Cost of Ownership (TCO) Over 10 Years
To help businesses plan better, here’s a TCO comparison between the DryGuide and DryGuide Essential over a 10-year period, considering maintenance, energy consumption, and initial purchase costs.
| Cost Category | DryGuide | DryGuide Essential |
| Wear & Tear Parts | £7,096.00 | £5,158.00 |
| Labour Time | 13 hours | 16 hours |
| Labour Cost* | £1,469.00 | £1,800 |
| Total Cost Over 10 Years: | £8,564.00 | £6,958.00 |
**Labour rate based on £113 per hour.
Breakdown of Total Cost of Ownership (TCO) Factors:
Initial Purchase Cost: The DryGuide has a higher upfront cost due to its larger motor and greater customizability. The Essential, designed for simplicity and smaller operations, comes in at a lower price point.
Energy Consumption: With its 15kW motor, the DryGuide consumes more energy, which adds up significantly over the years compared to the Essential’s more efficient 11kW system.
Maintenance Costs: The DryGuide’s belt-driven fan incurs higher maintenance costs due to the need for regular belt replacement, while the Essential’s direct-drive system is almost maintenance-free.
Overhaul Costs: Both systems may require major overhauls after 7–10 years, with DryGuide’s belt-driven system typically costing more due to its complexity.
What This Means for Your Business
The DryGuide Essential offers clear cost savings over time, particularly for businesses with lower production speeds and less frequent format changes. Its lower energy consumption and minimal maintenance requirements make it the more cost-effective option over a 10-year period.
For higher production environments, the DryGuide justifies its higher cost with increased capacity and greater flexibility. It offers a great return on investment for larger businesses that need maximum throughput and operational adaptability.
Summarising Strengths and Recommendations
Both the DryGuide and the DryGuide Essential offer exceptional drying performance, but each is designed to meet different production needs. Choosing the right machine depends on your production volume, budget, and operational complexity.
Strengths of the Original DryGuide:
- High-Speed Performance: The DryGuide excels in high-volume operations, capable of drying up to 125,000 cans or 80,000 bottles per hour. It’s ideal for businesses with large production lines needing rapid throughput.
- Modular Design: The original DryGuide allows for endless configurations, making it adaptable for varying formats, container sizes, and control requirements. This is essential for companies that frequently change between products or have complex regulatory needs. The modular design also accommodates customer future growth potential.
- Long-Term Durability: While the belt-driven blower requires periodic maintenance, it offers an extended lifespan, making it a reliable long-term investment for high-performance environments.
- Advanced Control Options: For production lines with stringent control specifications, the DryGuide’s fully customisable EcoPack control system ensures seamless integration into existing workflows, providing greater operational flexibility.
Strengths of the DryGuide Essential:
- Compact and Cost-Effective: The Essential’s 20% smaller footprint and 35% lower price make it ideal for smaller operations that don’t require the full capacity of the original model. This makes it a smart choice for businesses that are expanding but need to manage costs.
- Energy Efficiency and Low Maintenance: Powered by a direct-drive fan, the DryGuide Essential reduces maintenance intervals while maximising energy efficiency through its AirMinder controls. This is especially beneficial for operations where simplicity and reliability are key.
- Ease of Installation: With a top-mounted blower and ergonomic design, the DryGuide Essential is easier to install in space-constrained environments, making it an ideal solution for existing production lines that need an upgrade.
Recommendations:
- Choose the Original DryGuide if your operation demands high-speed production, frequent changes between container formats, or extensive control customisations. It’s perfect for businesses that need maximum flexibility and high performance at scale.
- Choose the DryGuide Essential if you run a smaller operation, have lower production speeds, or are looking for a more cost-effective yet reliable drying solution. It’s the ideal choice for businesses prioritising energy efficiency, lower upfront costs, and minimal maintenance.
Next Steps
Whether you’re looking to maximise throughput or optimise energy efficiency, Secomak’s DryGuide range offers a solution tailored to your needs. To learn more about how the DryGuide or DryGuide Essential can enhance your production line, visit our website for further details or contact our sales team at +44 (0) 208 732 1300, option 1, or email us at sales@secomak.com.
We’re here to help you choose the perfect drying solution for your business.
