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 exhaust air streams that contain not only volatile organic compounds (VOCs) but also high amounts of thermal energy. For occupational health and safety and environmental protection reasons, this air must not be discharged unfiltered – but at the same time, it offers great potential for savings.
oxytec offers modular solutions for exhaust air purification, including heat recovery, which enable you to produce in compliance with legal requirements while significantly improving your energy balance.
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Simply put your question to our AI. They will answer you individually:
Typical emission sources in 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 trimming / recycling | Thermally decomposed additives, VOCs, resin compounds | 90–150 °C, selective exposure |
| Further processing (e.g., lamination, printing) | Solvents, plasticizers, odorants | Depending on the process – often VOC-relevant |
Why combine cleaning and recovery in film extrusion?
- Odor and pollutant reduction for occupational safety and TA-Luft compliance
- Energy savings through recirculation of process heat
- Prevention of deposits in ventilation and heat exchangers
- No need for thermal post-combustion in low-VOC processes
- Eligible for funding through efficiency programs (BAFA, KfW, federal states)
Legal requirements
TA Luft 2021
- VOC limits for plastics processing companies
- Obligation to minimize organic emissions
- Energy-efficient cleaning is preferred by the authorities
BImSchG / 4. BImSchV
- Permit requirement above a certain volume flow/solvent consumption
- Measurement requirement for VOC and air quality in the workplace
EEWärmeG / GEG / EED
- Promotion of heat recovery from exhaust air as a climate protection measure
- Combined systems are considered to save primary energy
GIRL – Odor Emission Guideline
- Relevance for residential area boundaries or mixed zones
- oxytec systems significantly reduce odor-relevant components
Secure your energy and emission-free future – with Oxytec
Do you operate a film extrusion line or are you planning a new one?
Contact us—we will develop a customized solution for exhaust air purification and energy recovery.
Removes fine additive particles, wax residues, and oil mist
Protection for downstream heat exchangers
Can be integrated as a compact stainless steel block (optional)
Recovery from exhaust air for preheating fresh air or process air
Can be combined with heating or HVAC systems
Integrated condensate management for humid exhaust air
Efficient use in heating and process systems
Can be connected to heat pumps, solar systems, or buffer storage tanks
Ideal for reducing primary energy consumption
Typical areas of application
oxytec systems for exhaust air purification with heat recovery are used wherever warm, pollutant- or odor-laden exhaust air is produced—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 warm, moist exhaust air
Thanks to their modular design, the systems can be individually adapted to production volumes, temperature ranges, and pollutant profiles—for both new and existing plants.
Typical advantages of Oxytec systems
Efficient cleaning of hot, VOC-contaminated exhaust air
Recovery and utilization of process heat
Solutions without open flames – safe for plastics
Reduces contamination of the ventilation system
Eligible for subsidies, approval-compliant, future-proof
FAQ – Frequently Asked Questions
What emissions typically arise during film extrusion?
Extrusion mainly produces:
- VOCs (volatile organic compounds) from additives, plasticizers, and processing aids
- Vapors and mists at high temperatures
- Fine dust and aerosols, e.g., from anti-blocking agents or lubricants
- In later processing steps, solvents and odors may also be produced
These emissions can vary greatly depending on the type of polymer (PE, PET, PP, PA, etc.) and the process design.
Why is a simple filter or exhaust pipe not sufficient?
The emissions are often:
- Strong-smelling, even in low concentrations
- Soluble or sticky, leading to deposits in pipes
- Relevant to health and permits, e.g., in the case of VOC limits according to TA Luft
A pure exhaust air pipe often leads to odor nuisance 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 flameless, residue-free, and energy-efficient
It is particularly suitable for continuously warm process air, as typically occurs during extrusion.
How can you prevent heat exchangers from becoming dirty or clogged?
oxytec relies on:
- Upstream aerosol separators for grease, dust, and sticky residues
- Material-resistant heat exchangers made of stainless steel or special coatings
- Optional: automatic flushing or cleaning interval
This ensures that recovery and ventilation systems remain efficient in the long term.
How much energy can be saved through heat recovery?
Depending on the air temperature and volume flow, savings of 30–70% of exhaust air energy are realistic. The following can be recovered, for example:
- Warm air for fresh air preheating
- Hot water for cleaning or heating buildings
- Process heat for adjacent production stages
The payback period is often less than 2 years—especially in 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 provides support with selection and application.
What legal regulations do I need to observe?
- TA Luft 2021: Limit values for VOCs and organic emissions
- BImSchG / 4. BImSchV: Approval requirement for the entire plant, if applicable
- GIRL (Odor Emission Directive): if located near residential areas
- EEWärmeG, EED, GEG: Specifications for energy efficiency and recovery
Our systems are eligible for approval, comply with TA-Luft, and are ready for documentation.
How much maintenance is required?
The systems are designed for continuous industrial operation:
- UV lamps: approx. 8,000–10,000 operating hours
- Aerosol separators: clean every 2–3 months, depending on load
- Heat exchangers: virtually maintenance-free with pre-cleaning
- Optional: Remote monitoring and maintenance contract by oxytec
