KMA Environmental Technology References

Environmental Technology as a business case

Environmental protection only succeeds in industry if it pays off. Four projects from the foundry, food, plastics, and textile industries demonstrate how this looks in practice. The results are based on our customers’ operating data and have been published in the trade press.

-85% CO₂

compared to conventional production hall heating — always 18 °C in the production hall without gas

Foundry Example

14 t CO₂

instead of 1,132 t per year with thermal oxidation

Food Example

-98%

Operating costs compared to conventional thermal oxidation

Plastics Example

2.345 million kWh

energy recovered per year from stenter exhaust air

Textile Example

Emissions, Energy, Waste Heat – Engineered Together

Each of the four projects had its own starting point. We solved them using the same principle: exhaust air filtration, energy efficiency, and heat recovery are planned together, turning the obligation to comply with limit values into a business case.

In STIHL’s magnesium die casting foundry, 1,350 kW of recovered process heat now heats the production hall; CO₂ emissions have decreased by 85%, from 363 to 55 tonnes per year. The food manufacturer endori cleans its frying and roasting exhaust air without combustion, thus causing only 14 instead of 1,132 tons of CO₂ annually. Automotive supplier Valeo replaced its thermal oxidation with electrostatic precipitators, reducing operating costs from approximately €250,000 to €4,800 per year. And textile specialist AUNDE recovers 2.345 million kWh of energy each year from 24,500 m³/h of stenter exhaust air. All values are based on the operating data of the plant operators.

Foundry Example

A Foundry Heats with Waste Heat

Now: 55 tonnes of CO₂ per year

Previously: 363 tonnes of CO₂ per year from gas-fired hall heating

Heating costs per heating season: €36,000 → €5,900
Heating cost savings almost 84%
Production hall temperature 18 °C without gas

Magnesium die casting with approx. 6,000 t casting capacity per year and 13 air changes. Twelve KMA filter systems with heat exchangers on the production hall roof feed the central supply air system – implemented at the ANDREAS STIHL AG & Co. KG plant in Weinsheim.

Food Example

Clean Frying Exhaust Air – Without Natural Gas

Now: 14 tonnes of CO₂ per year

Previously: 1,132 tonnes of CO₂ with thermal oxidation

Operating costs over €290,000 → around €12,000
Natural gas 0 instead of 562,500 m³
Heat for supply air & process water

Plant-based meat and fish alternatives: 60–70 °C hot, fatty exhaust air with odours and VOC. Heat exchanger, electrostatic precipitator, UV light, and activated carbon catalyst in one module – implemented at endori in Stegaurach.

We put our trust in KMA

Plastics Example

Electrostatic precipitators instead of thermal oxidation

Now: €4.800 operating costs per year

Previously: €250,000 in operating costs per year with thermal oxidation

CO₂ per year 525 → 12 t
Separation efficiency min. 95%
Automatic cleaning, without removal

Vulcanization exhaust air from the extrusion of wiper blades: splitting products and plasticizers, up to 170 °C hot. A modular ULTRAVENT® M replaces thermal oxidation with over 750 °C – at an automotive supplier in the Stuttgart area (Valeo Wischersysteme).

Textile Example

Stenter Exhaust Air as an Energy Source

Now: 72 °C process heat

Previously: 16 °C, heated using additional energy

Energy 2.345 million kWh per year
CO₂ approx. 469 t less per year
Energy costs: −€93,800 per year

Two stenter frames with 24,500 m³/h exhaust air at approx. 140 °C, contaminated with oil smoke and fibers. The heat is 100% utilised internally for washing water and preheated fresh air, implemented at AUNDE Achter & Ebels in Mönchengladbach.

NO ONE LIKES TO INVEST IN EXHAUST AIR. ALL THE BETTER IF IT PAYS OFF.

Environmental technology is subsidised.

In the case of KMA systems, funding schemes typically focus on three aspects:

Replacing thermal emission treatment using natural gas / thermal oxidation (TO)
Recovering heat from industrial exhaust air improves energy efficiency and reduces usage of fossil fuels.
Energetic optimisations

Your exhaust air is an underestimated lever for decarbonization. Learn how to utilise it and receive funding here:

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Comply with emission limits Resolve odour problems Improve energy efficiency Use hot production exhaust air as an energy source

Ideas for utilising process heat for energy Clean air at the workplace / occupational health and safety Minimal maintenance effort for my exhaust air system

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