Anti-condensation system elevates aircraft performance and sustainability

The hidden challenge: Fuselage condensation

Fuselage condensation is a common but often overlooked issue in aircraft, especially during cruise and descent. When the cold fuselage surface meets moist cabin air, water vapor condenses inside the aircraft’s skin. This moisture accumulation can cause serious problems such as added weight, structural corrosion, and electrical failures, all of which impact aircraft safety and efficiency.

The weight of water: A cumulative burden

During flight, the fuselage skin can drop to temperatures as low as -25°C, while the cabin remains at around +24°C with typical relative humidity of approximately 15%. This temperature difference causes frost to form inside the insulation blankets, which then melts during descent and seeps into materials. Over time, this can add up to 300 kg of water weight in narrowbody aircraft and up to 600 kg in widebody planes. This extra weight increases fuel consumption and reduces payload capacity, driving up operational costs and environmental impact.

CTT Systems Anti-condensation solution

CTT Systems offers a cutting-edge Anti-condensation system designed to tackle this problem at its source. Using a parallel flow absorption dehumidifier with a silica gel-impregnated glass fiber honeycomb rotor, the system actively removes moisture from the crown area of the aircraft. It features a mixed-flow fan, heater, geared rotor drive motor, and controller that work together to maintain optimal humidity levels and prevent condensation.

From dry bliss to moisture management

The system creates a positive flow of dry air distributed through a piccolo duct along the fuselage crown. This dry air barrier absorbs moisture from insulation blankets, preventing it from reaching the cold aircraft skin and thereby stopping frost formation. Operating throughout the entire flight cycle, it keeps the space between the cabin and fuselage dry, eliminating moisture buildup and its harmful effects.

Environmental and economic impact

By removing between 200 and 600 kg of water weight, the Anti-condensation system significantly reduces fuel consumption by up to 21 tons annually and CO2 emissions by approximately 66 tons per aircraft. These savings result in lower operating costs and a smaller carbon footprint, thereby supporting airlines’ sustainability goals.

Fuel savings and decreased CO2 calculation​

For example, a 200 kg weight reduction on an Airbus A320neo or Boeing 737MAX results in:

• Fuel savings of about 21 tons per year
• CO2 emissions reduction of approximately 66 tons annually

Proven applications and benefits

CTT Systems has delivered over 3,000 Anti-condensation systems worldwide, both as retrofits and original equipment manufacturer (OEM) installations. Airlines report not only weight reductions but also a 40% decrease in unscheduled electrical component failures, leading to lower maintenance costs and improved operational reliability. The system also extends the lifespan of insulation blankets and reduces downtime caused by moisture-related issues.

In conclusion, reducing fuel burn and carbon footprint

CTT Systems’ Anti-condensation system is a breakthrough innovation that enhances aircraft performance, safety, and sustainability. By preventing fuselage condensation, it reduces excess weight, cuts fuel burn, lowers CO2 emissions, and minimizes costly moisture damage. This technology is a key step toward a more efficient, reliable, and environmentally responsible aviation future.

Anti-condensation system in your aircraft fleet
– reduces fuel burn and carbon footprint