Air Dryer Sizing Guide: Preventing Moisture Damage in Mid-South Industrial Facilities

In the Mid-South, moisture is not a minor inconvenience—it’s a constant reality. Facilities across Memphis, Jackson, Tupelo, Little Rock, and Springdale deal with high humidity for much of the year. When that moisture enters a compressed air system, it can cause corrosion, equipment damage, and production disruptions.

That’s why properly sizing an industrial air dryer is just as important as selecting the right compressor.

In 2026, moisture control isn’t optional—it’s essential for protecting uptime, product quality, and equipment lifespan.

Why Compressed Air Contains So Much Moisture

Atmospheric air always contains water vapor. In humid Mid-South conditions, that moisture level is especially high.

When air is compressed:

• Its temperature rises

• Its moisture content becomes concentrated

• As it cools, water condenses inside the system

Without a properly sized air dryer, that moisture travels through piping, tools, and equipment.

What Happens When Dryers Are Undersized?

Undersized air dryers are one of the most common problems found in older industrial facilities.

When a dryer is too small for system demand:

• It cannot handle peak airflow

• Dew point rises

• Moisture passes into the distribution system

• Corrosion accelerates

In humid environments like West Tennessee and North Mississippi, undersized dryers fail faster and allow more moisture through.

How to Properly Size an Industrial Air Dryer

Correct sizing depends on several key factors.

1. Required Airflow (CFM)

The dryer must match—or slightly exceed—the compressor’s maximum airflow capacity.

If your compressor produces 500 CFM, your dryer should be rated appropriately to handle that volume under real-world conditions.

2. Operating Pressure

Dryer performance ratings often assume specific pressure levels. Changes in system pressure affect airflow and drying capacity.

Facilities that adjust pressure to compensate for leaks or demand fluctuations may inadvertently overload their dryers.

3. Inlet Air Temperature

Higher inlet temperatures reduce dryer efficiency.

In the Mid-South, elevated compressor discharge temperatures during summer months mean dryers must be selected with real ambient conditions in mind—not laboratory ratings.

4. Desired Dew Point

Different applications require different moisture control levels.

• General manufacturing often uses refrigerated dryers

• More sensitive applications may require desiccant dryers

Understanding the dew point requirement is critical for proper sizing.

Refrigerated vs. Desiccant Dryers

Refrigerated Dryers

Common in most industrial applications, refrigerated dryers:

• Remove bulk moisture

• Maintain consistent dew points

• Offer lower operating cost

They are well-suited for many facilities in Memphis industrial corridors.

Desiccant Dryers

Desiccant dryers:

• Achieve much lower dew points

• Remove more moisture

• Are used for moisture-sensitive operations

They are often necessary for pharmaceutical, food-grade, or precision manufacturing processes.

Warning Signs Your Dryer Is Undersized or Failing

Many facilities don’t realize their dryer is the issue until symptoms appear:

• Water in air lines

• Rust in piping

• Tool malfunction

• Corrosion at fittings

• Increased maintenance on downstream equipment

If moisture-related issues increase during summer, dryer sizing may be inadequate.

Why Mid-South Humidity Makes Proper Sizing Critical

Facilities across Shelby County, North Mississippi, and Eastern Arkansas operate in one of the most humidity-heavy climates in the country.

High ambient moisture:

• Increases water load entering the compressor

• Shortens dryer lifespan

• Overwhelms marginal systems

Dryers that perform adequately in dry climates often struggle in the Mid-South without proper capacity margins.

Oversizing vs. Undersizing

While undersizing is dangerous, oversizing also has drawbacks:

• Higher upfront cost

• Reduced cycling efficiency

• Potential energy waste

The goal is precise sizing based on real operating conditions—not guesswork.

Why Dryer Sizing Should Be Part of a Full System Evaluation

Compressed air systems function as an integrated network. Dryer performance depends on:

• Compressor capacity

• Ambient conditions

• Piping design

• Airflow demand

• Pressure stability

Evaluating the entire system ensures the dryer is neither undersized nor improperly matched.

Protect Your Equipment From Moisture Damage

Moisture damage is expensive—but preventable.

Properly sized air dryers:

• Protect piping from corrosion

• Improve tool lifespan

• Stabilize production processes

• Reduce maintenance costs

• Improve overall system efficiency

Ignoring dryer sizing often leads to higher long-term repair costs than upgrading the system correctly.

Get Expert Help With Air Dryer Sizing

Process & Power helps facilities across Memphis, Jackson (TN), Tupelo (MS), Little Rock, and Springdale (AR) evaluate compressed air systems and properly size air dryers for Mid-South humidity conditions.

📍 1721 Corporate Avenue • Memphis, TN 38132
📞 (901) 362-5500

If moisture is affecting your compressed air system, a properly sized dryer can protect your operation and your equipment.