Labotek LESS (Labotek Energy Saving System) is an intelligent energy-saving solution developed to reduce energy consumption, increase process stability, and protect material quality in plastic processing plants, especially during the drying of hygroscopic polymers. LESS operates as an integrated system within centralised or stand-alone drying units, dynamically controlling drying air and temperature profiles, and delivers significant energy savings compared to conventional fixed-temperature drying systems.
LESS is a core component of Labotek's central drying solutions and is widely used for moisture-sensitive engineering plastics such as PET, PA, PBT, PC, and TPU.
LESS system working principle
In conventional drying systems, drying air is continuously generated at a fixed set temperature, while the condition of the return air is often ignored. The LESS system, however, manages the drying process not only based on the supply air temperature but also by continuously monitoring the return air temperature and overall process balance.
The working principle can be summarized as follows:
At the initial stage, the drying system reaches the preset nominal temperature. As moisture is removed from the material, the temperature of the return air increases. At this point, LESS uses the return air temperature as a reference and automatically reduces heater power. As a result, drying continues efficiently while unnecessary energy consumption is prevented and the material is protected from over-drying.
Thanks to this dynamic control logic, the drying air is continuously adjusted according to the real-time needs of the process.
Energy efficiency and savings impact
Depending on the application and material type, the LESS system can deliver approximately 20% to 40% energy savings in drying operations. These savings become even more significant in centralised drying systems and in plants operating multiple production lines over long periods.
The main reasons for energy savings include:
Prevention of heaters operating unnecessarily at full power
Efficient use of energy contained in return air
Reduction of heat losses caused by over-drying
More balanced and stable operation of system components
Contribution to material quality
LESS does not only reduce energy consumption; it also improves the stability of material quality. Over-drying can damage the molecular structure of certain polymers, cause colour changes, or reduce mechanical properties. The LESS system minimizes these risks by drying the material precisely to the required level in a controlled and balanced manner.
As a result:
Part surface quality becomes more consistent
Fluctuations in mechanical properties are reduced
Moisture-related production defects decrease
Scrap rates are lowered
Technical and system features
The LESS system is designed for full compatibility with Labotek's centralised and individual dryers. It is monitored via the dryer control unit and operates fully automatically without the need for operator intervention.
Key technical features include:
Return air temperature-based control algorithm
Automatic heater power modulation
Full integration with centralised drying systems
Compatibility with multi-material and multi-silo configurations
Industry 4.0-ready monitoring and control infrastructure
Application areas
LESS is especially preferred in applications with high energy demand and moisture-sensitive materials.
Typical application areas include:
PET preform and bottle blowing production
Injection moulding of PA- and PBT-based technical parts
Automotive and electrical/electronic components
Large production plants using centralised drying systems
24/7 production lines where energy costs are critical
Why Labotek LESS is preferred
LESS is not merely an energy-saving module; it is an intelligent control concept that makes the drying process smarter and more efficient. While reducing long-term energy costs, it also improves production quality and process reliability. In facilities operating with a centralised system philosophy, the LESS system provides a strong competitive advantage in terms of environmental sustainability and total cost of ownership.