Condair & Humidity Control
Condair Group AG is the world’s leading manufacturer of industrial and commercial humidification systems. The Swiss-headquartered company’s products are used in hospitals, pharmaceutical plants, data centres, museums, libraries and other critical environments worldwide. The Defensor product family is one of the most successful series, combining ultrasonic and adiabatic humidification technology for the most efficient air moisturising.
Carbon Composites began working with the Condair Group in 2012, when the company was looking for a new supplier for the Defensor humidifier plastic housings. The previous injection-moulded solutions did not fully meet quality expectations, particularly regarding surface quality and corrosion resistance. High-pressure reactive injection-moulded (PU-RIM) urethane composite technology offered an excellent alternative to these challenges.
Advantages of the PU-RIM Urethane Solution
Humidifier units operate in extremely humid environments where conventional materials can quickly corrode or degrade. PU-RIM urethane housings offer outstanding corrosion resistance, ensuring a long service life even under the most demanding conditions. The urethane material does not rust, does not degrade from moisture and resists most cleaning agents.
Thermal properties were also important during development. Urethane’s low thermal conductivity helps maintain the unit’s optimum operating temperature while reducing condensation on external surfaces. This not only improves energy efficiency but is also beneficial from a hygiene perspective, as it reduces the chance of bacteria and mould colonisation.
Aesthetic appearance is a key priority for Condair, since the units are frequently installed in visible locations within office buildings, shopping centres or healthcare facilities. The smooth, uniform surface of the urethane housings and the available colour options help blend the equipment harmoniously into modern interiors.
Manufacturing Technology
Defensor housings are produced using PU-RIM (Polyurethane Reaction Injection Moulding) with a Hennecke high-pressure piston metering machine. In PU-RIM two reactive components – polyol and isocyanate – are mixed at high pressure, then the reactive blend is injected into a closed mould where the material reacts and solidifies into a rigid urethane housing. The process delivers excellent surface quality, complex internal geometry and reproducible mechanical properties.
The moulds are CNC-machined from aluminium, ensuring the required dimensional accuracy and long tool life. Carbon Composites manufactures and maintains the production moulds in its own tool shop, enabling fast turnaround when design changes are needed. Mould temperature control ensures uniform reaction progression and proper curing cycles.
After curing the housings are deflashed and post-machined to create precise contours and openings. Final surface treatment includes textured painting in the ordered RAL colours.
Quality Assurance & Testing
Every production batch undergoes strict quality inspection. Incoming material checks include verifying polyol and isocyanate component certificates and documenting storage conditions. During production, process parameters – mixing pressure, mould temperature, reaction time – are continuously monitored and recorded.
Tests carried out on finished housings include dimensional inspection, visual and instrumental surface-quality assessment, and regular testing of mechanical test specimens. Water-resistance tests simulate actual operating conditions, ensuring long-term reliability.
Logistics & Collaboration
Condair operates a JIT (Just-In-Time) supply system, requiring flexible production capacity and reliable delivery performance from its suppliers. Carbon Composites has developed a dedicated stock strategy that ensures continuous supply despite seasonal demand fluctuations. During the winter heating season, demand for humidifiers increases significantly, requiring advance capacity planning.
Communication between the development and production teams is continuous. Regular technical reviews ensure that any design modifications are implemented quickly and efficiently. Carbon Composites proactively suggests improvements that reduce costs or enhance product properties.
Results & Development Directions
Since the collaboration began, more than 2,000 humidifier housings have been delivered to Condair, serving in numerous countries around the world. The complaint rate is minimal – a result of consistent production quality. Customer satisfaction surveys consistently give excellent ratings for both product quality and supplier services.
In line with Condair’s sustainability strategy, Carbon Composites continuously seeks ways to reduce the environmental footprint of production, whether through energy efficiency, waste reduction or material selection.