Energy Costs Slashed

A multi-national flexible packaging manufacturer in Korea had an existing Bobst Lemanic Rotogravue press producing cigarette cartons. The business needed a second line to meet growing demand. However, there was a big concern that the fuel cost to operate the associated Thermal Oxidiser would be prohibitively high.

The original Bobst press used gas fired heating for the dryers and exhausted around 40,000 m3 /hr of solvent air to the Oxidiser. The oxidiser was sized at 80,000 m3 /hr. With a propane gas cost of US $2.3 cents per kW. The gas consumption was 10.8 million kW per year at a cost for US $250,000 and with a CO2 emissions of 2,326 tonnes.

It was estimated that bringing in a second line would increase the gas consumption to 21.6 million kW per year at a cost of US $500,000 and 4,652 tonnes of CO2 emissions.

Operational designed a bespoke optimisation and control system able to reduce the combined exhaust air flow rate leaving the two presses from 80,000mᶾ/hr to 32,000mᶾ/hr. Operational provided Electrical and Control Engineers from the UK during the installation and Process Commissioning Engineers during final commissioning.

The overall result is that the oxidiser currently consumes 9.2 million kW of gas per year with 1.994 tonnes/year of CO2 emissions. LPG fuel consumption has been reduced by 12.4 m3 kW an overall reduction of 57%. This provided a return on investment in 1 year based on original gas prices.

The Engineering Manager commented “This was a great collaboration that worked really well.”


Benefits: Fuel Consumption reduced by 12.4million kW per year.

Environmental Impact: CO2 emissions reduced by 2,658 Tonnes per year.

Cost savings: US$400,000 per year.

Payback: 1 year.

Call us today to find out how Operational can help you improve your process and slash your energy costs.

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