Improve Safety Process & Significant Plant Energy Savings

Development and installation of a controllable and safe LEL system

A major international Packaging Company, recognised industry leader in plastic, fibre, metal and glass packaging products, needed to improve safety and compliance with 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 press dryers were operating inefficiently causing production problems and poor product quality. The high flow rates from the dryers were over loading the VOC abatement system and utilising excessive quantities of gas as support fuel.

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 with dryers 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 functionally tested before handover to the customer.

The project involved interfacing with and commissioning the emission control system, and backed up with a scheduled service and maintenance program for the complete system to ensure continued optimum performance.


Customer: Major International Printing Company.

Initial Situation: High energy costs at the regenerative thermal oxidiser (RTO) and poor product quality due to inefficient dryer operation.

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.

Customer Statement: Operational were able to develop and install a controllable and safe system which is of high quality, performs well and saves us money.

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

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