A packaging film manufacturer achieved continuous emissions compliance, reliable round-the-clock operation, and significant fuel consumption reduction by implementing Epcon’s high-capacity Regenerative Thermal Oxidizer (RTO) system. Designed for high VOC volumes from solvent-based printing and coating lines, the RTO provides reliable destruction efficiency while integrating heat recovery to drastically lower operating costs.
Packaging Film Manufacturing – High-Capacity VOC Abatement with Heat Recovery
Executive Summary
Project Overview
A packaging film producer required robust emissions control for solvent-based printing, coating, and lamination processes operating continuously. VOC emissions were substantial and variable, demanding a solution capable of maintaining compliance without disrupting high-throughput production. Energy efficiency and uptime reliability were key business concerns due to the 24/7 nature of the operation.
Epcon engineered an RTO system designed for high-capacity, round-the-clock emissions control to meet both regulatory and production requirements.
Epcon engineered an RTO system designed for high-capacity, round-the-clock emissions control to meet both regulatory and production requirements.
The Challenge
Packaging film production generates large volumes of VOC-laden exhaust that must be treated consistently. The customer needed a solution to address:
- Continuous operation with variable solvent loading and high airflow rates.
- Mandatory requirement for high VOC destruction efficiency (DRE).
- Minimizing fuel usage and reducing overall operating cost.
- Ensuring system stability and reliability to prevent production downtime.
- Requirement for integrated heat recovery to improve energy efficiency.
The Solution
Epcon delivered a Regenerative Thermal Oxidizer system engineered for continuous VOC destruction and optimized energy efficiency.
Regenerative Thermal Oxidizer (RTO) Design
Regenerative Thermal Oxidizer (RTO) Design
- The RTO is designed for high-capacity airflow to handle large-volume exhaust from multiple printing/coating lines.
- It utilizes ceramic heat exchange media to capture thermal energy from the exhaust stream.
- The captured thermal energy is reused to preheat incoming VOC-laden air.
- This regenerative process significantly reduces auxiliary fuel demand and dramatically lowers overall operating costs.
- The system is built for round-the-clock, continuous operation with high reliability.
- PLC-Based Controls ensure stable performance across varying process conditions, managing combustion and airflow with precision.
Technical Specifications
Feature / Component | Specification / Benefit |
Oxidizer Type | Regenerative Thermal Oxidizer (RTO) |
Capacity | ~30,000 SCFM |
VOC Destruction | ≥99% Destruction Efficiency |
Heat Recovery | Regenerative Ceramic Media for Energy Reuse |
Operating Mode | Continuous Operation |
Control System | PLC-Based Combustion and Flow Control |
Design Intent | High-Capacity, Low Fuel Consumption, High Reliability |
The Results
“The RTO has run flawlessly since commissioning, giving us total peace of mind on compliance and a noticeable drop in our monthly fuel bill.”
The installed system delivered measurable operational and environmental benefits:
The installed system delivered measurable operational and environmental benefits:
- Achieved continuous emissions compliance for solvent-based processes.
- Significantly reduced fuel consumption due to integrated heat recovery.
- Provided stable, reliable operation with minimal operator intervention.
- Supported uninterrupted packaging film production and improved sustainability performance.
Industry
Applications
This advanced RTO system is ideal for high-throughput, continuous-operation manufacturing where solvent-based VOC abatement is required, including:
- Packaging and Flexible Film Manufacturing
- Printing and Web Coating Lines
- Laminating and Converting Operations
- General High-Volume Industrial Coating
Next Steps
Achieve Continuous Compliance and Reduce Fuel Costs
Your film manufacturing or coating line requires high-capacity, reliable emissions control with a focus on cost reduction. Epcon’s regenerative thermal oxidizer is engineered to deliver guaranteed 99% VOC destruction while dramatically lowering your fuel usage through efficient heat recovery. If your process requires high-capacity, continuous VOC abatement or a system designed to maximize energy efficiency for round-the-clock operation, your next step is simple. Contact our specialized RTO engineering team directly for a custom application study, or initiate a chat now to answer a quick technical question on process integration.
Your film manufacturing or coating line requires high-capacity, reliable emissions control with a focus on cost reduction. Epcon’s regenerative thermal oxidizer is engineered to deliver guaranteed 99% VOC destruction while dramatically lowering your fuel usage through efficient heat recovery. If your process requires high-capacity, continuous VOC abatement or a system designed to maximize energy efficiency for round-the-clock operation, your next step is simple. Contact our specialized RTO engineering team directly for a custom application study, or initiate a chat now to answer a quick technical question on process integration.
Contact Epcon for Custom Solutions
Epcon offers full engineering, fabrication, and installation of afterburner-based thermal oxidizers, quench systems, wet scrubbers, and full emissions-control lines — customized for chemical, petrochemical, and industrial gas-stream applications.If your facility handles acid gases, H₂S, solvent exhaust, or other challenging emissions, contact our engineering team to discuss a tailored solution.
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