Exhaust air filtration
and
smoke extraction
for die casting
Reduce mould-release agent mist in the production hall, improve your energy efficiency and meet relevant requirements – with solutions specifically designed for die casting machines.
How to combine environmental protection & profitability
With our evironmental technology, you unlock multiple potentials at once: you cut energy costs through intelligent heat recovery, sustainably reduce emissions and create better working conditions in your production.
This lets you combine environmental protection and profitability in one step – while also securing competitive advantages. Our many best-practice projects impressively show how efficiency and sustainability can be successfully combined in die casting foundries.
Think sustainably.
Secure the future.
Measurably reduce CO₂ emissions. Meet ESG targets and safeguard your investments with clean, durable systems. This turns sustainability into a real competitive advantage.
Use energy smartly.
Cut costs noticeably.
Maximum efficiency through smart heat recovery and holistic energy solutions. Less energy consumption, no follow-up costs from filter replacement – and minimal maintenance. That saves money, time and resources.
Healthy air.
Strong performance.
Clean, emission-free air in the production hall boosts wellbeing, motivation and safety. Your employees work more productively – your systems stay clean and high-performing.
KMA offers proven solutions for all die casting processes
Aluminium cold-chamber die casting
KMA is at home in aluminium die casting – across the full spectrum: from standard processes to large castings, for die casting machines of all clamping forces. In this highly productive process, liquid aluminium is pressed into steel moulds under high pressure; the result is dimensionally accurate, fine-surfaced components that are both lightweight and stable.
Magnesium cold-chamber die casting
KMA knows the special requirements and delivers suitable solutions for improved fire protection: magnesium is flammable and reacts violently at high temperatures with oxygen, water and extinguishing water; in die casting, these properties therefore require strict safety precautions along the entire process chain.
Hot-chamber die casting
KMA also has the right solutions for hot-chamber die casting for zinc and magnesium: in this highly productive process, zinc alloys are pressed into moulds under high pressure; this produces components that combine enormous precision, excellent flow properties and exceptional mechanical strength.
clean air.
save energy.
>3,000
Systems installed worldwide
80 %
Energy savings possible compared to conventional exhaust air technology
360°
Emissions, exhaust air and energy. Engineered together.
1,500+
Customers worldwide trust our technology
We put our trust in KMA
“Our systems are equipped with the most advanced, energy-optimised exhaust air and evironmental technology. This means DGS not only contributes to CO2 reduction through its products (…), but starts doing so in the manufacturing process at the casting cells.”
Andreas Müller, former CEO, DGS Druckguss Systeme AG
Our solution for die casting machines
Air quality in die casting: tackle emissions at the source
Without air management
Roof and hall openings do not ensure sufficient air quality. Smoke and oil mist spread through the production hall, endanger employees and contaminate the plant technology.
With hall ventilation
Active hall ventilation requires high capacities for an effective air change rate and fresh air zones at the workstations.
Local smoke extraction of emissions in exhaust air mode
Smoke extraction hoods capture pollutants directly at the source
and reduce the exhaust air volume.
Decentralised smoke extraction hood in recirculation air mode
The smoke extraction hoods capture pollutants at the source, the ULTRAVENT filters the exhaust air and returns it to the production hall in purified form.
ULTRAVENT® III:
The efficiency exhaust air pro for die casting
For over 30 years, our environmental technology engineers at KMA have been developing bespoke systems for smoke extraction, exhaust air purification and heat recovery in foundries.
With the modular ULTRAVENT®, KMA Umwelttechnik GmbH offers an exhaust air filter system developed for foundries.
KMA offers various solutions for hood design and filter placement
Smoke extraction hood
one-piece
Smoke extraction hood
two-piece
Smoke extraction hood
two-piece, movable
Smoke extraction hood and filter
Filter on a separate platform
Smoke extraction hood with piping
The exhaust air expert for die casting.
Maximum efficiency & best in class
The strongest standard specification in the industry
Over 3,000 systems in use worldwide
You are currently viewing a placeholder content from YouTube. To access the actual content, click the button below. Please note that doing so will share data with third-party providers.
More InformationThe energy-saving KMA ULTRAVENT® exhaust air filter system
Effective exhaust air filtration
ULTRAVENT® exhaust air filter systems are modular and therefore extremely flexible:
Depending on the exhaust air load, the appropriate filter units are combined and, if required, equipped with a heat recovery system.
Retrofitting the filter to meet increased requirements is also possible.
Energy-saving heat recovery
Especially in cold regions, heating fresh air is very energy-intensive and therefore costly. KMA heat recovery systems recover valuable process waste heat from the exhaust air and make it usable for heating the air in the production hall.
This delivers energy savings of up to 80% compared to conventional exhaust air technology.
Unique cleaning system
Thanks to the integrated automatic KMA cleaning system (Cleaning in Place “CIP”), the ULTRAVENT® III operates powerfully, reliably and with low maintenance effort. The many programming options of the cleaning system increase service convenience for the user of the filter system. Our proven cleaning system impresses customers worldwide and minimises unwanted interruption time of the production system.
KMA solutions for die casting machines
Renault - Tailor-made solutions for different sites
How does Renault achieve consistent environmental and occupational health and safety standards across different sites – despite completely different conditions? Using Valladolid and Togliatti as examples, the article shows how tailor-made filter concepts improve air quality and significantly reduce energy use.
DGS – climate protection as a competitive advantage
Rising energy prices and CO₂ costs are making climate protection in foundries a hard economic factor – DGS shows how to turn it into a competitive advantage. Learn how the company reduced its CO₂ footprint by over 90% in 6 years and relies on energy-efficient exhaust air technology worldwide.
Nemak – heat recovery in magnesium die casting
Conventional exhaust air systems move air volumes – and thus energy and heating costs – unnecessarily high. Learn how Nemak achieves high pure air quality with point-source capture, high-performance filtration and recirculation of the purified air, keeping heat smartly in the process.
Frequently asked questions about exhaust air filtration in die casting
Does KMA extraction fit die casting machines from all manufacturers?
Yes — ULTRAVENT® systems are designed independently of the manufacturer and are used on all common die casting machines (e.g. Bühler, Colossio, Frech, Haitian, IDRA, Italpresse, LK, Maico, OMS, Yizumi). We customise the Extraction hood, filter placement and control interfaces individually to the respective casting cell — as a retrofit on existing machines as well as ex works on new systems. The basis is over 2,000 systems we have developed for the die casting industry. Send us your machine list — we will check the connection for each machine.
Does KMA cover all casting materials — aluminium, zinc and magnesium?
Yes — the extraction and filter technology applies equally to aluminium, zinc and magnesium die casting. In all cases, the mould-release agent aerosols and fumes from the casting process are separated; with magnesium, a fire protection concept along the process chain is added due to the metal’s flammability. A reference for magnesium is the STIHL die casting plant with over 20 hot- and cold-chamber machines. Tell us the material and process — the design takes both into account.
When do you recommend recirculation air mode, and when exhaust air mode?
Recirculated air when maximum energy efficiency matters: the purified air stays in the production hall along with the heating heat, saving up to 80% energy compared to classic exhaust air technology. Exhaust air mode is chosen when process heat is to be extracted in a targeted way or when the permitting situation requires discharge — often with integrated heat recovery. Key factors are the hall climate, the site’s heat demand and the requirements of VDI 2262-3 for pure-air recirculation. We can calculate both variants for your production hall.
Do I need extraction even with minimum quantity spraying (MMS)?
Yes — minimum quantity spraying reduces the water, not the oil. The total sprayed amount drops drastically, but the amount of mould-release agent it contains remains practically unchanged. What disappears is the visible water vapour — the oil smoke, however, forms from the mould-release agent and remains: it is what settles in the production hall and burdens the air you breathe. With conventional spraying, around 3 litres of mixture are applied per cycle, diluted 1:80 to 1:120, containing about 25 to 30 ml of mould-release agent; with oil-based MMS it is 30 to 50 ml per cycle, just almost undiluted. At 100,000 cycles per year, that is 3,000 to 5,000 litres of mould-release agent per casting cell — multiplied by the number of your cells. Less mist therefore does not mean less smoke: MMS can change the required exhaust air volume, but it does not make capture at the source unnecessary. Send us your spraying protocol — we will design the system for your actual mould-release agent quantity.
What should you look for in a filter system for die casting machines?
Five points: energy efficiency, separation performance, interfaces to the machine, maintenance convenience and durability. With the ULTRAVENT® III, energy efficiency is already built into the filter design: electrostatic separation creates hardly any air resistance, the system requires only 1.1 to 4.2 kW and saves over 80% energy compared to mechanical filters — the ECO+ control with speed synchronisation to the spraying cycle adds up to 40% more. CIP cleaning works without filter media replacement; remote maintenance is optionally integrated. A die casting machine runs for a good 25 years — the filter system is designed for that. Details can be found in the ULTRAVENT® III brochure in the download area.
Why does experience matter when designing evironmental technology in die casting?
An extraction hood can be replicated. The design behind it cannot — and certainly not an integrated concept for exhaust air, waste heat and emissions that makes the entire site more energy-efficient. We helped develop exhaust air purification in die casting decades ago, setting the standard by which the market is guided today. Drawing on our experience with over 2,000 systems, we know how release agents, cycle times and workshop conditions affect exhaust air purification, what specifications the major OEMs set, and where a smaller foundry can make sensible savings. This practical expertise is incorporated into every design — just as it is in the areas that go beyond this today: exhaust air management in megacasting, heat recovery from melting furnaces, and the use of this heat for the energy-efficient foundry of tomorrow. You therefore benefit not only from effective smoke extraction at the die casting machine, but also, if required, from a concept for your entire site — and from the experience that underpins it.
Your direct contact
Talk to Kerem Kartal
Would you like to know how smoke extraction, exhaust air filtration and heat recovery can be effectively combined on your die-casting machines?
Let’s work together to determine which system design is best suited to your site, both technically and in terms of energy efficiency. The starting point is always the actual layout of your machinery and premises.
Our die casting solutions in the trade press
Publications & technical articles
We are the expert
Further applications
More information
Downloads & links
Laws & guidelines
TA-Luft: Air pollution control – emission limit
VDI 2262-3: Workplace air quality – pure-air recirculation
TRGS 900: Workplace limit values