AFTERMARKET MONDAY: Hot Bypass Stack: Critical for Press Line Expansions

July 14, 2025 -Aftermarket Monday

Hot Bypass Stack: Critical for Press Line Expansions

Expanding Your Press Lines? Don’t Ignore the Thermal Pressure

When industrial plants add new press lines — especially in composites, thermoforming, or coating applications — the existing air pollution control system often can’t handle the additional thermal load. That’s where a hot bypass stack becomes essential.

If your oxidizer or heat exchanger isn’t upgraded with a properly engineered bypass path, you’re risking:

• System Overheating & Unplanned Shutdowns
• Reduced VOC Destruction Efficiency
• Thermal Stress on Heat Exchangers & Burners
• Permit Violations During Dynamic Load Changes

What Is a Hot Bypass Assembly?

A complete hot bypass system includes:

• Valve and actuator
• Bypass ducting and dampers
• Temperature and pressure controls
• Logic and sequencing integration

It diverts excess high-temperature process air away from the oxidizer during spikes—relieving thermal pressure and protecting the system.

Signs You Need One

✅ You’re adding press lines or increasing throughput
✅ Your RTO has overheated during spikes or startups
✅ Stack test margins are getting tighter
✅ Burner adjustments can’t keep up with fluctuations

S&SE Aftermarket Expansion Support

At Ship & Shore Environmental, we evaluate whether a hot bypass is:

• Required for system safety or code compliance
• Needed to maintain high destruction efficiency
• Justified by fuel savings or equipment protection

We design, fabricate, and integrate full bypass systems with no disruption to production.

One thermoforming client avoided a $250K oxidizer replacement by adding a hot bypass stack to stabilize temperatures during peak loads.

Don’t Wait Until the System Trips

Adding presses? Planning a facility expansion? 

This is the time to future proof your oxidizer and build in the safety, flexibility and efficiency your system needs.

📞Let’s schedule a site assessment and see if a bypass upgrade can future-proof your system.

Categorised in: 25Years of S&SE, aftermarket, Air pollution, AM Monday, Flexographic, Industry news, News, Ship & Shore, Technical, VOC Abatement