#TechTalk: Next-Level VOC & Ozone Abatement for the Flexographic and Packaging Industry

#TechTalk: Next-Level VOC & Ozone Abatement for the Flexographic and Packaging Industry

August 27, 2025

For 25 years, Ship & Shore Environmental (SSE) has been a trusted partner to the flexographic printing and laminating industry, providing innovative and reliable solutions for VOC and ozone control. Celebrating our 25th anniversary in September 2025, SSE has successfully completed hundreds of projects, establishing a reputation for engineering excellence, regulatory expertise, and operational efficiency.

Packaging That Captures Attention – Responsibly

Packaging is everywhere—from the breakfast cereal you reach for in the morning to the evening snack you enjoy. Eye-catching designs, high-gloss finishes, laminations, and dimensional printing all help products stand out on shelves. Food, pharmaceutical, paper, film, and corrugated packaging companies compete for consumer attention through unique, high-impact visuals.

To achieve these results, printing facilities rely on inks and coating designed for optimal finish and durability. While water-based coatings contain minimal solvents, solvent-based materials are still widely used, especially in high-speed flexographic operations—producing significant amounts of Volatile Organic Compounds (VOCs) and hydrocarbon emissions. Regulatory agencies mandate that these emissions be captured and treated to protect both the environment and worker health.

Why Emissions Control Matters

VOCs released into the atmosphere combine nitrogen oxides and sunlight to form smog, a proven contributor to respiratory illnesses. Some solvents are classified as Hazardous Air Pollutants (HAPs) and are carcinogenic. Additionally, corona treatment equipment—used to enhance surface energy for better ink adhesion—produces ozone emissions that are highly corrosive, hazardous to health, and increasingly regulated in air quality permits.

Regenerative Thermal Oxidizers: Industry-Standard Abatement

To address these challenges, Ship & Shore designs and install Regenerative Thermal Oxidizers (RTOs), the preferred technology in modern printing and packaging facilities. Our Clean-Tech RTOs can destroy up to 99% of VOCs and HAPs through high-temperature oxidation (approximately 1450–1500°F). With thermal efficiencies reaching up to 97%, RTOs minimize natural gas usage and operating costs while ensuring regulatory compliance. They are durable, reliable, and equipped with PLC-controlled HMI interfaces for seamless operation.

Tailored Solutions for Every Facility

SSE provides end-to-end abatement solutions, including:

• Full equipment design and fabrication
• Ductwork and collection system engineering
• Regulatory permitting support
• After-sales service and maintenance
• Assistance with rebates and utility incentives to reduce capital and operating costs

The efficiency of an RTO depends heavily on upstream ductwork and collection systems. Poorly designed systems can lead to oversized or undersized oxidizers, excessive energy use, and regulatory non-compliance. SSE optimizes airflow and capture efficiency, allowing smaller, smarter RTO systems that reduce natural gas consumption, electrical load, and overall operating costs. Key strategies include:

• Permanent Total Enclosure (PTE) designs for press decks
• Cascading or recirculating airflow to minimize total volume
• Targeted ducting for aging versus new presses
• Modular layouts for future expansion
• T-Damper isolation for non-operating lines to reduce unnecessary fresh air treatment

Advanced Ozone and VOC Management

Corona treaters generate Ozone to improve ink adhesion, but uncontrolled ozone can corrode equipment and harm workers. SSE integrates ozone treatment into existing RTO systems or uses catalyst solutions, ensuring emissions comply with the 8-hour, time-weighted average exposure standard of 0.1 ppm. All ductwork is fabricated from corrosion-resistant materials and designed for optimal exhaust placement.

Delivering Maximum Value with Every Project

Investing in VOC and ozone abatement involves capital, manpower, permitting, and energy considerations. SSE maximizes project value by:

• Understanding individual printing processes to select the best oxidizer technology
• Minimizing airflow to reduce RTO size while utilizing VOCs as fuel to lower energy costs
• Exploring secondary heat recovery to further reduce operating expenses
• Planning for future process changes
• Coordinating with environmental engineers and permitting authorities
• Securing rebates and incentives through local natural gas and electrical utility programs

A Partner in Growth and Compliance

Ship & Shore’s engineers work closely with plant personnel to design systems that integrate seamlessly with manufacturing processes. By combining technical expertise, hands-on engineering, and a deep understanding of the printing industry, SSE ensures:

• Improved air quality
• Enhanced energy efficiency
• Regulatory compliance
• Lower operational costs and maximum profitability

Proven Leadership in the Printing Industry

SSE has continuously advanced alongside the printing world, assisting facilities with:

• Industry-leading RTO designs for efficient, low-maintenance operation
• Enhanced collection efficiency through PTEs and sweep air technology
• Fine-tuning ductwork to maximize VOC capture and fuel value
• Proper ozone treatment integration for corona treaters
• Leveraging rebates, incentives, and secondary heat recovery opportunities

Whether you are establishing a new operation, expanding existing presses, or upgrading abatement systems, consulting with Ship & Shore Environmental ensures that your facility remains compliant, energy-efficient, and cost-effective.

Contact us at service@shipandshore.com or call (562) 997-0233.

Categorised in: #CleanAirSolutions, #MadeInAmerica, #VOC Control, 25Years of S&SE, DirectFired, Ship & Shore, Technical, TechTalk, ThermalOxidizer, VOC Abatement