#TechTalk: Delivering Reliable Air Pollution Control for a Packaging Manufacturer
September 29, 2025 11:24 am#TechTalk: Control Engineering – Delivering Reliable Air Pollution Control for a Packaging Manufacturer
September 29, 2025
Client Challenge
A leading packaging and printing manufacturer was under pressure to meet increasingly strict VOC emission limits while maintaining full-scale production. Their existing air pollution control (APC) system combination of thermal oxidizers and scrubbers—struggled with:
- Variable Process Conditions: Rapid shifts in VOC loads and flow rates depending on production schedules.
- Operational Complexity: Outdated controls required frequent manual intervention, leading to errors and downtime.
- Compliance Risks: The lack of robust safety interlocks and proper system validation exposed the client to potential regulatory penalties.
The client needed a custom-engineered control solution that could adapt dynamically to production demands, simplify operator interaction, and guarantee continuous compliance.
Ship & Shore’s Approach
Ship & Shore Environmental was engaged to modernize and re-engineer the client’s control system. Our control engineers applied a comprehensive approach covering the entire project lifecycle:
- Commissioning & Start-Up: Supervised installation, fine-tuned sequencing, and verified real-time system performance.
- Factory Acceptance Testing (FAT): Conducted rigorous testing prior to shipment, validating every control logic sequence, interlock, and instrument response.
- Integration & Optimization: Seamlessly integrated the APC system with plant operations, allowing real-time adjustments to VOC fluctuations.
- Remote Monitoring & Diagnostics: Installed advanced monitoring capabilities, enabling predictive maintenance and fast troubleshooting support.
Technical Solutions Implemented
Ship & Shore’s team introduced advanced automation features, including:
- PLC Programming & Logic – Automated sequencing optimized for variable VOC destruction loads.
- HMI Redesign – A modern, intuitive operator interface for streamlined usability.
- Instrumentation & P&ID Enhancements – Upgraded mapping and sensors for precise monitoring and process control.
- Safety Interlocks – Integrated fail-safe systems to guarantee compliance and protect plant personnel and assets.
Results
The re-engineered control system delivered measurable improvements:
- 98% VOC Destruction Efficiency, ensuring compliance with stringent packaging industry air regulations.
- 30% Reduction in Downtime, achieved through automation and remote support features.
- Simplified Operations, with an operator-friendly HMI reducing manual interventions.
- Verified Compliance, confirmed through comprehensive FAT, SAT, and field-testing protocols.
Client Impact
With Ship & Shore’s solution, the packaging manufacturer eliminated compliance risks, improved system reliability, and ensured uninterrupted production. The client not only achieved regulatory peace of mind but also strengthened their reputation as a responsible, environmentally conscious producer.
Conclusion
This project highlights how Ship & Shore Environmental leverages advanced control engineering to solve complex APC challenges in the packaging industry. By combining precision automation, rigorous validation, and collaborative execution, Ship & Shore delivered a tailored, dependable, and compliant solution—helping the client operate efficiently while protecting the environment and their community.
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📧 Email: service@shipandshore.com
Categorised in: #CleanAirSolutions, #MadeInAmerica, #VOC Control, 25Years of S&SE, Ship & Shore, Technical, TechTalk, ThermalOxidizer, VOC Abatement