Most classic humidifiers use some type of florist foam as the moisture source. This foam can get moldy and clogged with the by-products of fermentation, and they simply don’t last that long. Within a year or two, you have to replace them. However, there are many newer products that can be used within your existing humidifier cassette that will last virtually forever. Recently, I started retrofitting my different humidifier cassettes with superabsorbent polymers, though you can also use silica gel (“humidification beads”).

First you need to buy some of your humidification product. Both polymers and silica gel are very inexpensive when purchased in bulk. I bought 2 pounds of polymers for $15 (USD). A single pound will last a lifetime, so I split the cost with a buddy.

Then, buy a sheet of flexible plastic mesh, the kind used for needlework. You can find this in any hobby shop and it’s cheap. I used a number 7 mesh. Cut the mesh to the exact size of the cassette and cut two pieces, one for the top and one for the bottom.

Finally, you whip up a batch of the polymers. To set up and use polymers, you mix distilled water and propylene glycol (PG) and then place them in the humidification cassette in your humidor. The use of wetting solution or PG with silica gel or polymers is to moderate the relative humidity and to prevent mold growth. Since PG does not evaporate as readily as water, it will slow the release of fluid from the beads and serve to regulate the RH levels. You may have to play with the mixture a bit to get it just right (my recipe for the polymers is below).

In the top photo at left, you can see the cassette filled with polymers, the top sheet of mesh and the removed foam (green). The next photo shows the polymers before (left) and after (right) being saturated with water. These little nuggets will hold up to 400 times their weight in fluid. The bottom photo shows how to recharge the cassette. I have opened the cassette in this photo so you can see the polymers, but normally you won’t have to open the cassette, just pour distilled water in a plastic container and let the cassette sit in the water, the polymers will suck up the moisture. I recharge the polymers about once a month. [Note: most silica beads come pre-charged, but recharging the silica beads is a bit different. You will need to open the cassette and use a spray bottle to lightly mist the beads until they are about 70% clear. Also, you do NOT use PG with silica gel.]

My recipe for a small batch of polymers is as follows:

•  Put in 1-1 ½ tablespoons of dried polymers into a medium sized plastic container.

•  Stir in 2/3 cups of distilled water. Don’t mix it in all at the same time. Allow some time for the beads to take up the fluid and keep stirring to make sure the beads are evenly wet.

•  Also mix in ½  - 1 cup of a wetting solution (i.e., a PG distilled water mixture). You can find wetting solution at any cigar shop.

•  Keep stirring the mixture so that the polymers are evenly wet.

•  Then let sit for at least two hours before using, or overnight for optimum absorption.

•  After overnight hydration, discard any excess fluid and you’re ready to rock and roll.

•  To recharge beads, simply pour in a little distilled water every few weeks.

•  If beads become discolored over time, just toss them and cook up a new batch.

Doc