Humidity and condensation management in the fruit and vegetable sector

Case study: Installation of TOR extraction towers and ACF air circulators in a processing environment with high humidity and steam.

In fruit and vegetable processing warehouses, humidity is a constant presence. Incoming produce is wet, washing and sorting processes generate constant water vapor, and ambient temperatures fluctuate between product preservation needs and line operation. When the air isn’t moving, humidity stratifies, condenses on the ceiling, and falls onto work surfaces. This is precisely the problem we addressed for a fruit and vegetable company, installing a combination ofTOR seriesextraction towers andACF circulatorsto restore microclimate control in the department.

The problem

The fruit and vegetable sorting and washing departments handle products with a high water content. The steam generated during washing and handling quickly accumulates in the air, especially in the higher areas of the department where the walls and ceiling are colder. The temperature difference between the rising humid air and the cold surfaces triggers condensation, which collects on the ceiling, forms drops, and falls back onto the production line.

The consequences are tangible and measurable. Wet surfaces encourage bacterial growth and make it more difficult to comply withHACCP hygiene requirements. Downtime for extraordinary cleaning takes away production time. Condensation reaching electrical components accelerates their deterioration, increasing the likelihood of failure.

The company did not have a forced ventilation system in the affected department. The situation relied solely on natural air circulation, which was insufficient in an environment that continuously generates humidity throughout the operating day.

Why humidity in produce departments is a technical challenge

The temptation, when faced with a humid environment, is to resort to the first available extractor fan. But the logic of “the more air moving, the better” isn’t enough in contexts like this.

The problem of stratification is physical: hot, vapor-laden air rises and accumulates at high altitudes, while colder, drier air remains at the bottom. If only the air at the top is extracted without moving the air at the bottom, a discontinuous flow is created that fails to resolve condensation in the intermediate zones and fails to protect the working surfaces from falling droplets.

The effective solution is not just extraction, but to combine extraction with forced circulation. Exhaust towers remove saturated air from the environment. Circulators break up the stratification, continuously mix the air, and prevent the formation of humid layers that trigger condensation. The two components work in a complementary manner. Without circulation, extraction is only partially effective, while without extraction, circulation redistributes humidity without eliminating it.

This logic guided the technical choice for the intervention.

On-site inspection and choice of solution

Before finalizing the solution, we conducted an on-site inspection of the department, analyzing the steam sources, the space’s volumes, the layout of the production line, and the ceiling’s construction features. The photos taken during the visit show a space with sandwich panels on the ceiling and walls, conveyor lines with blue plastic crates, and PVC strip curtains separating the areas. This is a typical setting for the modern fruit and vegetable industry, with stringent hygiene requirements and the need for operational continuity.

The analysis confirmed the absence of any mechanical ventilation system and highlighted the presence of multiple steam sources distributed along the line. The technical response needed to be proportionate to this distribution, not concentrated in a single point.

The system installed

The solution we have designed includes two distinct and complementary components.

• TheTOR seriesexhaust towers were installed on the ceiling, positioned to uniformly cover the entire area of ​​the department. Their purpose is to create a constant flow of exhaust air that carries saturated air outward, preventing it from accumulating in the upper areas of the room.
• Termotecnica Pericoli’sACF circulatorscomplete the system. Installed at strategic points throughout the department, they generate a horizontal airflow that breaks down stratification, continuously mixes the ambient air, and prevents the formation of saturated layers that cause condensation on the ceiling. The stainless steel frame and peraluman impeller make them suitable for the hygienic requirements of the food industry.

The result is a dual-level ventilation system. Circulation prevents stratification, while extraction eliminates excess humidity. The combination of the two is essential for maintaining a stable microclimate throughout the entire production day.

Results obtained

The installed system has eliminated the problem of condensation on the ceiling and walls of the department. The air is kept in constant motion, stratification is prevented, and the steam produced by the line is extracted before reaching the cold surfaces where it would condense.

From a hygiene standpoint, the department now complies with HACCP requirements for microclimate control, with dry surfaces throughout the operating day. Downtime for extraordinary cleaning due to condensation has been eliminated.

The production line’s electrical components, previously exposed to excess humidity, now operate under controlled conditions, reducing the risk of failures related to moisture penetration into the windings and circuits.

Working in a produce department means dealing with an environment that produces humidity structurally, not occasionally. Installing an extractor fan isn’t enough; it’s important to understand how the air behaves in that specific space and design a system that addresses all aspects of the problem. This is what distinguishes a solution that lasts over time from one that only works in the first few weeks.

Do you have a department facing similar challenges?Do you have a department facing similar challenges? Request a technical configuration or learn more about theextraction towersandACF circulatorswe’ve installed.

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