CASE STUDY – Optimizing VOC Collection and RTO Performance for Flexographic Printing

CASE STUDY – Optimizing VOC Collection and RTO Performance for Flexographic Printing

Project Overview

A U.S. flexographic printing facility faced increasing VOC emissions as production expanded. Uneven airflow, aging ductwork, and inadequate source capture challenged emissions control while increasing energy demand and limiting future growth.

Ship & Shore Environmental (S&SE) engineered an integrated VOC collection system and regenerative thermal oxidizer (RTO) solution to improve capture, optimize exhaust flow, and support reliable operation.

Engineering Challenges

• Uneven airflow across existing and new presses.
• Fugitive solvent emissions from insufficiently enclosed areas.
• Excessive exhaust volume and duct resistance increasing fan energy demand.
• Fluctuating process conditions affecting oxidizer operation.
• Limited flexibility for future production expansion.

S&SE’s Engineering Solution

S&SE prioritized collection efficiency before finalizing system requirements, addressing airflow at its source rather than simply accommodating existing inefficiencies.

• Source Capture: Engineered hoods and permanent total enclosure (PTE) design to direct VOC-laden exhaust toward treatment.
• Airflow Balancing: Optimized duct routing and exhaust distribution to reduce unnecessary airflow while maintaining effective capture.
• Adaptive Controls: Variable-frequency-drive (VFD) fans to adjust airflow in response to operating conditions.
• Thermal Efficiency: Regenerative ceramic media to recover heat and reduce supplemental fuel demand.
• Combustion Management: Low-NOx burner technology and automated controls to support stable operation.
• Future Expansion: Modular ductwork designed to simplify connections for additional presses.

System Configuration

The design specified a 25,000 SCFM RTO, integrated with engineered ductwork, source-capture components, and coordinated controls.

Expected Operational Benefits

The integrated approach targets improved VOC collection, more consistent oxidizer operation, lower avoidable fan energy consumption, and reduced fuel demand through regenerative heat recovery. Modular design also supports future production changes.

Actual capture efficiency, destruction performance, energy savings, and regulatory compliance must be verified through project-specific testing and applicable permit requirements.

Key Takeaway

Effective VOC control starts with effective collection. By integrating source capture, balanced airflow, regenerative heat recovery, and adaptable controls, S&SE helps flexographic printers pursue efficient emissions management and scalable production.

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📧 Email: service@shipandshore.com