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Exhaust air purification in printing plants – VOCs, solvents, and odors safely under control

The common printing processes of offset printing, flexographic printing, and gravure printing generate significant exhaust air pollution from volatile organic compounds (VOCs), solvents, moisture, odors, and some reactive substances. Whether sheet-fed printing, web printing, or packaging printing—wherever inks, varnishes, cleaning agents, or adhesives are used, contaminated air enters the production room or the surrounding area.
oxytec offers customized exhaust air purification systems that reliably remove VOCs and odors—energy-efficient, low-maintenance, and compliant with legal requirements.

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Typical emission sources in the printing process

Process Typical emissions Special features
Offset printing (sheet/roll) Isopropanol, dampening solution, ink mist High VOC load, diffuse escape, odor pollution
Flexographic printing / gravure printing Ethyl acetate, toluene, glycol ether Solvent-intensive inks, ATEX-relevant
Digital printing / UV printing Acrylates, ozone, photoinitiators Strong odors, low air volumes, varying exposure
Varnishing/coating VOCs, silicones, additives Combined emissions, often strong-smelling
Cleaning/color change Acetone, IPA, ethanol Short-term emission peaks during equipment or roller cleaning

Why is exhaust air purification necessary in printing plants?

  • VOCs pose a risk to health and the environment
  • Solvents are often flammable or toxic (ATEX)
  • Odors cause complaints from employees and residents
  • Many printing companies require approval in accordance with the Federal Immission Control Act (BImSchG)
  • TA Luft and VOC guidelines prescribe specific emission limits
  • Without exhaust air treatment, there is a risk of downtime, fines, or restrictions

Legal requirements

  • TA Luft (2021): VOC, particulate matter, and odor limits
  • 31. BImSchV (VOC Regulation): Reduction obligations for over 2 t VOC/year
  • VOC Directive (2010/75/EU): Requirements for low-emission technologies
  • ATEX zones: for flammable solvents, paints, and cleaners

oxytec provides support with approvals, certifications, and communication with authorities.

Request a consultation now – for clean air in your print shop

Would you like to operate your printing processes in compliance with legal requirements, solve odor problems, and treat VOCs safely?

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oxytec technologies for the printing industry

UV ozone systems

Decomposes VOCs, paint mist, and odors through photochemical reaction—without combustion or chemicals.

Suitable for:

  • Offset printing rooms
  • Dryer exhaust air
  • Hall air with diffuse VOC sources

Advantages:

  • Energy efficient (only electricity)
  • Compact design
  • Low maintenance

activated carbon filter

Adsorbs residual VOCs and odors – ideal as a secondary stage or for fluctuating pollution levels.

Suitable for:

  • Paint and cleaning rooms
  • UV or solvent printing
  • Small print shops without central extraction systems

KAT Industry

Activated carbon filter as a storage reactor for air post-treatment

Hybrid solutions and special equipment

Combinations with moisture removal, heat recovery, or air conditioning are possible depending on the printing process.

Examples of use

  • Offset printing (newspapers, brochures, packaging)
  • Flexographic printing & label printing (e.g., on film, paper, cardboard)
  • Digital printing on large formats, sheets, or rolls
  • UV printing companies with ozone and acrylate exposure
  • Finishing and further processing with varnishes, adhesives, coatings

Your advantages with oxytec exhaust air systems

  • Effective against VOCs, ozone, odors, and paint mist
  • Energy efficient – no gas, no burner
  • Space-saving & retrofittable
  • Low maintenance & durable – ideal for 3-shift operation
  • Support with funding and approval processes

FAQ – Frequently Asked Questions

Which VOCs typically occur in a printing plant?

Depending on the process, the following may be produced:

  • Isopropanol (IPA) from dampening solutions (offset)
  • Ethyl acetate, toluene, MEK, glycol ether from paints, varnishes, and adhesives
  • Acetone, ethanol from cleaning agents
  • Acrylates, photoinitiators, ozone in UV or digital printing

Some of these substances are harmful to health, have a strong odor, are flammable, or are ATEX-relevant.

How does UV ozone technology work to reduce VOCs?

Our systems combine:

  • UV-C emitters that activate oxygen to form ozone
  • Ozone reaction, which oxidatively splits VOCs
  • Odor elimination through oxidation of organic substances

The process is residue-free, energy-efficient (only electricity) and does not require open flames or combustion.

How reliably do UV systems work with fluctuating emissions, e.g., due to color changes?

Highly reliable – Oxytec systems:

  • respond quickly to load changes
  • Can be expanded modularly as needed
  • can be combined with activated carbon as a buffer stage

This means that even short-term peaks, e.g., during cleaning or color changes, can be easily controlled.

How can exhaust air purification be integrated into existing systems?

Oxytec systems are compact, modular, and can be retrofitted.
They can be installed:

  • directly on the dryer exhaust air
  • centrally for entire hall areas
  • decentrally on individual machines

Installation is also possible during ongoing operation – without stopping production.

What limits must I comply with as a printing company?

The following are relevant:

  • Total emissions according to TA Luft and VOC Directive
  • Maximum VOC quantities according to 31. BImSchV
  • Odor concentrations according to GIRL (Odor Emission Directive)
  • For UV printing, also ozone emissions indoors

We support you in legally compliant planning and documentation. How energy-intensive is a UV/activated carbon exhaust air system?

How energy-intensive is a UV/activated carbon exhaust air system?

Highly efficient – depending on the system, energy consumption is between:

  • 0.2–1.5 kWh per 1000 m³ of air
  • No gas connection, no flames
  • Also suitable for combination with heat recovery

Compared to thermal afterburning, you save significantly on operating costs.

What funding opportunities are available for exhaust air purification in printing companies?

Funding is available for:

  • VOC reduction measures (e.g., DEHSt / BAFA / state funds)
  • Energy efficiency measures as part of investments
  • Emission technologies for new plants or modernization

oxytec assists with subsidy research, project documentation, and application submission.

How often is maintenance required?

Maintenance requirements are low:

  • UV lamps: Replacement approx. every 8,000 operating hours
  • Activated carbon: Replacement every 6–12 months, depending on load

Systems can be monitored remotely, with optional automatic fault reporting

How is compliance with VOC limits verified?

Our systems can be equipped with:

  • Measuring connections for emission tests
  • Automatic operating logging (e.g., air volume, running time)
  • Interfaces to BDE or control systems

We support you in preparing for official measurements and approval procedures.