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Exhaust air purification after film extrusion – neutralizing VOCs

oxytec systems for low-emission production and usable exhaust air energy

The production of plastic films by extrusion generates hot, polluted exhaust air streams, which not only contain volatile organic compounds (VOCs), but also high amounts of thermal energy. This air must not be discharged unfiltered for reasons of occupational health and safety and environmental protection – but at the same time offers great potential for savings.

oxytec offers modular solutions for exhaust air purification including heat recovery, with which you can produce in compliance with the law and at the same time significantly improve your energy balance.

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Typical sources of emissions during film extrusion

Emission source Typical pollutants Special features / temperature range
Extrusion zone VOCs from polymer additives, condensates, vapors 80-140 °C, hot and continuous
Extraction and cooling Fine dust, mist, additive particles 40-80 °C, partly condensing
Edge trim / recycling Thermally decomposed additives, VOCs, resin compounds 90-150 °C, punctual exposure
Further processing (e.g. lamination, printing) Solvents, plasticizers, odorous substances depending on the process – often VOC-relevant

Why combine cleaning & recovery in film extrusion?

  • Odor and pollutant reduction for occupational safety and TA-Luft conformity
  • Energy savings through recirculation of process heat
  • Avoidance of deposits in ventilation and heat exchangers
  • Elimination of thermal post-combustion for low-VOC processes
  • Eligible for funding through efficiency programs (BAFA, KfW, federal states)

Legal requirements

TA Luft 2021

  • VOC limit values for plastics processing companies
  • Obligation to minimize organic emissions
  • Energy-efficient cleaning is preferred by the authorities

BImSchG / 4th BImSchV

  • Requirement for approval from a certain volume flow/solvent consumption
  • Obligation to measure VOC and air quality at the workplace

EEWärmeG / GEG / EED

  • Promotion of heat recovery from exhaust air as a climate protection measure
  • Combined systems are considered primary energy-saving

GIRL – Odor Immission Directive

  • Relevance for residential area boundaries or mixed zones
  • oxytec systems significantly reduce olfactory relevant components

Secure your energy and zero emissions – with Oxytec

Do you operate a film extrusion line or are you planning a new line?

Contact us – we will develop a customized solution for exhaust air purification and energy recovery.

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oxytec systems for extrusion exhaust air

UV ozone systems for VOC neutralization

Converts VOCs and odorous substances into CO₂ and water

Chemical-free, low maintenance

No flame risk – ideal for plastics processing

Operation also possible in humid, hot air (>100 °C)

Aerosol separator with pre-filtration

Removes fine additive particles, wax residues and oil mist

Protection of downstream heat exchanger

Can optionally be integrated as a compact stainless steel block

Heat recovery systems (WRG)

Recovery from exhaust air to preheat fresh air or process air

Can be combined with heating or HVAC systems

Integrated condensate management for humid extract air

Condoheat – recirculation of the recovered heat

Efficient use in heating and process systems

Can be coupled with heat pumps, solar or buffer storage tanks

Ideal for reducing the use of primary energy

Typical areas of application

oxytec systems for exhaust air purification with heat recovery are used wherever warm, polluted or odorous exhaust air is generated – especially in processes with high energy consumption:

  • Plastics processing (extrusion, injection molding, thermoforming)
  • Film and packaging production
  • Painting and coating processes
  • Textile and paper finishing
  • Food production (frying, baking, deep-frying)
  • Chemical-technical processes with VOC content
  • Wood and furniture industry (presses, resins, dryers)
  • Cleaning and CIP processes with hot, humid exhaust air

Thanks to the modular design, the systems can be individually adapted to production volumes, temperature ranges and pollutant profiles – for new and existing systems alike.

Typical advantages with oxytec systems

Efficient cleaning of hot, VOC-contaminated exhaust air

Recovery and utilization of process heat

Solutions without an open flame – safe for plastics

Reduces soiling of the ventilation system

Eligible for subsidies, approval-proof, future-proof

FAQ – häufige Fragen

What emissions are typically produced during film extrusion?

Extrusion mainly produces:

  • VOCs (volatile organic compounds) from additives, plasticizers and process aids
  • Vapors and mists at high temperatures
  • Fine dusts and aerosols, e.g. from anti-blocking agents or lubricants
  • In later processing steps, possibly also solvents and odors

These emissions can vary greatly depending on the type of polymer (PE, PET, PP, PA, etc.) and the process.

Why is a simple filter or exhaust air pipe not enough?

The emissions are frequent:

  • Odorous, even in low concentrations
  • Soluble or sticky, which leads to deposits in pipes
  • Relevant to health and approval, e.g. with VOC limit values according to TA Luft

A pure exhaust air pipe often leads to unpleasant odors in the surrounding area, problems with the authorities or deposits in the technology.

How does Oxytec’s UV ozone technology work in film extrusion?
  • UV-C light generates ozone and activates oxygen radicals
  • These oxidize organic pollutants such as VOCs and odorous substances
  • Only CO₂ and H₂O are produced as residual products
  • The method is flame-free, residue-free and energy-efficient

It is particularly suitable for continuously warm process air, which is typically generated during extrusion

How do you prevent heat exchangers from getting dirty or sticking?

oxytec relies on:

  • Upstream aerosol separators for grease, dust and sticky residues
  • Material-resistant heat exchanger made of stainless steel or special coatings
  • Optional: automatic rinsing or cleaning interval

This keeps recovery and ventilation systems permanently efficient.

What energy savings are possible with heat recovery?

Depending on the air temperature and volume flow, savings of 30 – 70 % of the exhaust air energy are realistic. The following can be recovered, for example

  • Warm air for fresh air preheating
  • Hot water for cleaning or building heating
  • Process heat for adjacent production stages

The amortization time is often less than 2 years – especially with continuous operation.

Is the technology eligible for funding?

Yes, the following are eligible:

  • VOC reduction measures
  • Energy efficiency projects with heat recovery
  • Investments in environmentally friendly exhaust air technology

Relevant programs:

  • BAFA Module 4 (cross-sectional technologies)
  • KfW funding programs for industrial efficiency
  • State programs for environmental and climate protection

oxytec supports you in the selection and application process.

What legal regulations do I have to observe?
  • TA Luft 2021: Limit values for VOCs and organic emissions
  • BImSchG / 4th BImSchV: if applicable, approval requirement for the entire system
  • GIRL (Odor Immission Directive): in case of proximity to residential areas
  • EEWärmeG, EED, GEG: Requirements for energy efficiency and recovery

Our systems are approvable, TA-Luft-compliant and ready for documentation.

How time-consuming is the maintenance?

The systems are designed for continuous industrial operation:

  • UV lamps: approx. 8,000 – 10,000 operating hours
  • Aerosol separator: clean every 2-3 months depending on load
  • Heat exchanger: practically maintenance-free with pre-cleaning
  • Optional: Remote monitoring and maintenance contract by oxytec

What would you like to know?

Simply put your question to our AI. They will answer you individually:

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would like a quotation?

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oxytec s.r.o
Revoluční 1082/8
11000 Prague

FON: +42 07 229 084 26
FAX:  +49 40 480 967 72
Mail:  polak@oxytec.cz

Your contact person:
Ing. Jiri Polák

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