Improved Safety Process & Significant Plant Energy Savings

A major international Packaging Company, recognised industry leader in plastic, fibre, metal and glass packaging products, needed to improve safety and compliance to fall within the Solvent Emission Directives. The company also wanted to enhance the control of the drying systems for improved efficiency, product quality and plant safety.

The company could not rationalise their existing volatile organic compounds (VOC) collection and abatement system as exhaust airflow rates were too high and out of control. This was costing money and wasting energy.

Operational designed, supplied and installed a tailor-made solution which incorporated an LEL control system for each dryer and washing machine. In addition, improvements were made to the layout and control of the centralised exhaust collection system. Various machines were converted from gas to thermal oil. Once the design and engineering phases were complete, a detailed risk assessment was undertaken and the agreed design taken through the procurement and installation phases. The new system was started up and fully tested before handover to the customer.

The project involved interfacing with and commissioning the emission control system, and was backed up with service and maintenance of the whole system on a regular basis.

  • Customer: Major International Printing Company
  • Initial Situation: High energy costs at the regenerative thermal oxidiser (RTO).
  • Solution: Tailor-made LEL control system for each dryer; Dryer technology upgrades; Installation of safety systems.
  • Client Benefits: Exhaust airflow reduced from 230,000 to 120,000 m³/h; Reduction in heat loss to atmosphere of up to 1,000 kW
  • Payback: Less than 2.5 years