{"id":27432,"date":"2026-05-11T15:34:11","date_gmt":"2026-05-11T13:34:11","guid":{"rendered":"https:\/\/www.kma-filter.de\/exhaust-air-purification-and-heat-recovery-for-die-casting\/"},"modified":"2026-11-04T16:13:41","modified_gmt":"2026-11-04T15:13:41","slug":"exhaust-air-purification-and-heat-recovery-for-die-casting","status":"publish","type":"page","link":"https:\/\/www.kma-filter.de\/en\/industries-applications\/exhaust-air-purification-and-heat-recovery-for-die-casting\/","title":{"rendered":"Exhaust air filtration and heat recovery for die casting"},"content":{"rendered":"\t\t
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Exhaust air filtration\nand
smoke extraction
for die casting<\/h1>\t\t\t\t<\/div>\n\t\t\t\t
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Reduce mould-release agent mist in the production hall, improve your energy efficiency and meet relevant requirements \u2013 with solutions specifically designed for die casting machines.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t

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\n\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\n\t\t\t\t\t\t\t\t\tSolution & technology<\/span>\n\t\t\t\t\t<\/span>\n\t\t\t\t\t<\/a>\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t
\n\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\n\t\t\t\t\t\t\t\t\tCustomer examples<\/span>\n\t\t\t\t\t<\/span>\n\t\t\t\t\t<\/a>\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t
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\n\t\t\t\t\tYour potential in die casting<\/span>\t\t\t\t<\/div>\n\t\t\t\t
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How to combine environmental protection & profitability<\/h2>\t\t\t\t<\/div>\n\t\t
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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.<\/p>

This lets you combine environmental protection and profitability in one step \u2013 while also securing competitive advantages. Our many best-practice projects impressively show how efficiency and sustainability can be successfully combined in die casting foundries. <\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t

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\"Icon-Industry-Accent\"<\/figure>

Think sustainably.
Secure the future.<\/h3>

Measurably reduce CO\u2082 emissions.\nMeet ESG targets and safeguard your investments with clean, durable systems.\nThis turns sustainability into a real competitive advantage.<\/p><\/div><\/div>\t\t\t\t<\/div>\n\t\t\t\t

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\"Icon-Energy-Accent\"<\/figure>

Use energy smartly.
Cut costs noticeably.<\/h3>

Maximum efficiency\nthrough smart heat recovery and holistic energy solutions.\nLess energy consumption,\nno follow-up costs from filter replacement \u2013\nand minimal maintenance.\nThat saves money, time and resources.<\/p><\/div><\/div>\t\t\t\t<\/div>\n\t\t\t\t

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\"Icon-Occupational-health-and-safety-circle-green\"<\/figure>

Healthy air.
Strong performance.<\/h3>

Clean, emission-free air in the production hall boosts wellbeing, motivation\nand safety. \nYour employees work more productively \u2013 your systems stay clean and high-performing.<\/p><\/div><\/div>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t

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KMA offers proven solutions for all die casting processes<\/h2>\t\t\t\t<\/div>\n\t\t
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\"Pure<\/figure>

Aluminium cold-chamber die casting<\/h3>


KMA is at home in aluminium die casting \u2013 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. <\/p><\/div><\/div>\t\t\t\t<\/div>\n\t\t\t\t

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\"STIHL<\/figure>

Magnesium cold-chamber die casting<\/h3>


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.<\/p><\/div><\/div>\t\t\t\t<\/div>\n\t\t\t\t

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\"RST<\/figure>

Hot-chamber die casting<\/h3>


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.<\/p><\/div><\/div>\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t

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clean air.
save energy.<\/b><\/h2>\t\t\t\t<\/div>\n\t\t
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>3,000<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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Systems installed worldwide<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t

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80 %<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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Energy savings possible compared to conventional exhaust air technology<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t

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360\u00b0<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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Emissions, exhaust air and energy. Engineered together.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t

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1,500+ <\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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Customers worldwide trust our technology<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t

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We put our trust in KMA<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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\"DGS
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\"GF
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\"Harting
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\"BMW
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\"IDRA
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\"Volvo
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\"DAIHATSU
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\"VW
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\"Magna
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\"Nemak
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\"DAIMLER
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\"Renault
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\"VOIT
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\u201cOur 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.\u201d<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t

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Andreas M\u00fcller, former CEO, DGS Druckguss Systeme AG<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t

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Our solution for die casting machines<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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Air quality in die casting: tackle emissions at the source<\/h2>\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t
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Without air management<\/strong><\/p>

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. <\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t

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With hall ventilation<\/strong><\/p>

Active hall ventilation requires high capacities for an effective air change rate and fresh air zones at the workstations.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t

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Local smoke extraction of emissions in exhaust air mode<\/strong><\/p>

Smoke extraction hoods capture pollutants directly at the sourceand reduce the exhaust air volume.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t

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Decentralised smoke extraction hood in recirculation air mode<\/strong><\/p>

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.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t

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ULTRAVENT\u00ae III:\n
The efficiency exhaust air pro for die casting<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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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.<\/p>

With the modular ULTRAVENT\u00ae, KMA Umwelttechnik GmbH offers an exhaust air filter system developed for foundries.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t

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\n\t\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\t\n\t\t\t\t\t\t\t\t\tMore info about the ULTRAVENT\u00ae III<\/span>\n\t\t\t\t\t<\/span>\n\t\t\t\t\t<\/a>\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t
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ULTRAVENT\u00ae III combined with a KMA smoke extraction hood<\/figcaption>\n\t\t\t\t\t\t\t\t\t\t<\/figure>\n\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t
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KMA offers various solutions for hood design and filter placement<\/h2>\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t
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Smoke extraction hood
one-piece<\/h3><\/div><\/div>\t\t\t\t<\/div>\n\t\t\t\t
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Smoke extraction hood
two-piece<\/h3><\/div><\/div>\t\t\t\t<\/div>\n\t\t\t\t
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Smoke extraction hood
two-piece, movable<\/h3><\/div><\/div>\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t
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Smoke extraction hood and filter<\/h3><\/div><\/div>\t\t\t\t<\/div>\n\t\t\t\t
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Filter on a separate platform<\/h3><\/div><\/div>\t\t\t\t<\/div>\n\t\t\t\t
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\"KMA<\/figure>

Smoke extraction hood with piping<\/h3><\/div><\/div>\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t
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The exhaust air expert for die casting.<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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\n\t\t\t\t\t\t\n\t\t\t\t\t\t\tMaximum efficiency & best in class\t\t\t\t\t\t<\/span>\n\t\t\t\t\t<\/h3>\n\t\t\t\t\n\t\t\t\t\n\t\t\t<\/div>\n\t\t\t\n\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t
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\n\t\t\t\t\t\t\n\t\t\t\t\t\t\tThe strongest standard specification in the industry\t\t\t\t\t\t<\/span>\n\t\t\t\t\t<\/h3>\n\t\t\t\t\n\t\t\t\t\n\t\t\t<\/div>\n\t\t\t\n\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t
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\n\t\t\t\t\t\t\n\t\t\t\t\t\t\tOver 3,000 systems in use worldwide\t\t\t\t\t\t<\/span>\n\t\t\t\t\t<\/h3>\n\t\t\t\t\n\t\t\t\t\n\t\t\t<\/div>\n\t\t\t\n\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t
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You are currently viewing a placeholder content from YouTube<\/strong>. To access the actual content, click the button below. Please note that doing so will share data with third-party providers.<\/p> More Information<\/a> <\/div>

Unblock content<\/a> Accept required service and unblock content<\/a> <\/div> <\/div> <\/div><\/div><\/div>\t\t\t\t
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The energy-saving KMA ULTRAVENT\u00ae exhaust air filter system<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t

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Effective exhaust air filtration<\/h3>

ULTRAVENT\u00ae 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.<\/p><\/div><\/div>\t\t\t\t<\/div>\n\t\t\t\t

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Energy-saving heat recovery<\/h3>

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.<\/p><\/div><\/div>\t\t\t\t<\/div>\n\t\t\t\t

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Unique cleaning system<\/h3>

Thanks to the integrated automatic KMA cleaning system (Cleaning in Place \u201cCIP\u201d), the ULTRAVENT\u00ae 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\u2028of the production system. <\/p><\/div><\/div>\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t

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\n\t\t\t\t\tCustomer examples in die casting<\/span>\t\t\t\t<\/div>\n\t\t\t\t
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KMA solutions for die casting machines<\/h2>\t\t\t\t<\/div>\n\t\t
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\"Die<\/figure>

Renault - Tailor-made solutions for different sites<\/h3>


How does Renault achieve consistent environmental and occupational health and safety standards across different sites \u2013 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. <\/p><\/div><\/div>\t\t\t\t<\/div>\n\t\t\t\t

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\"Die<\/a><\/figure>

DGS \u2013 climate protection as a competitive advantage<\/a><\/h3>


Rising energy prices and CO\u2082 costs are making climate protection in foundries a hard economic factor \u2013 DGS shows how to turn it into a competitive advantage. Learn how the company reduced its CO\u2082 footprint by over 90% in 6 years and relies on energy-efficient exhaust air technology worldwide.
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Nemak \u2013 heat recovery in magnesium die casting<\/h3>


Conventional exhaust air systems move air volumes \u2013 and thus energy and heating costs \u2013 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.
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Frequently asked questions about exhaust air filtration in die casting<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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Does KMA extraction fit die casting machines from all manufacturers? <\/div><\/span>\n\t\t\t\t\t\t\t\n\t\t\t<\/path><\/svg><\/span>\n\t\t\t<\/path><\/svg><\/span>\n\t\t<\/span>\n\n\t\t\t\t\t\t<\/summary>\n\t\t\t\t
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Yes \u2014 ULTRAVENT\u00ae systems are designed independently of the manufacturer and are used on all common die casting machines (e.g. B\u00fchler, 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 \u2014 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 \u2014 we will check the connection for each machine. <\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/details>\n\t\t\t\t\t\t

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Does KMA cover all casting materials \u2014 aluminium, zinc and magnesium? <\/div><\/span>\n\t\t\t\t\t\t\t\n\t\t\t<\/path><\/svg><\/span>\n\t\t\t<\/path><\/svg><\/span>\n\t\t<\/span>\n\n\t\t\t\t\t\t<\/summary>\n\t\t\t\t
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Yes \u2014 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\u2019s 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 \u2014 the design takes both into account. <\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/details>\n\t\t\t\t\t\t

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When do you recommend recirculation air mode, and when exhaust air mode? <\/div><\/span>\n\t\t\t\t\t\t\t\n\t\t\t<\/path><\/svg><\/span>\n\t\t\t<\/path><\/svg><\/span>\n\t\t<\/span>\n\n\t\t\t\t\t\t<\/summary>\n\t\t\t\t
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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 \u2014 often with integrated heat recovery. Key factors are the hall climate, the site\u2019s heat demand and the requirements of VDI 2262-3 for pure-air recirculation. We can calculate both variants for your production hall. <\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/details>\n\t\t\t\t\t\t

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Do I need extraction even with minimum quantity spraying (MMS)? <\/div><\/span>\n\t\t\t\t\t\t\t\n\t\t\t<\/path><\/svg><\/span>\n\t\t\t<\/path><\/svg><\/span>\n\t\t<\/span>\n\n\t\t\t\t\t\t<\/summary>\n\t\t\t\t
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Yes \u2014 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 \u2014 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 \u2014 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 \u2014 we will design the system for your actual mould-release agent quantity. <\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/details>\n\t\t\t\t\t\t

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What should you look for in a filter system for die casting machines? <\/div><\/span>\n\t\t\t\t\t\t\t\n\t\t\t<\/path><\/svg><\/span>\n\t\t\t<\/path><\/svg><\/span>\n\t\t<\/span>\n\n\t\t\t\t\t\t<\/summary>\n\t\t\t\t
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Five points: energy efficiency, separation performance, interfaces to the machine, maintenance convenience and durability. With the ULTRAVENT\u00ae 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 \u2014 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 \u2014 the filter system is designed for that. Details can be found in the ULTRAVENT\u00ae III brochure in the download area. <\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/details>\n\t\t\t\t\t\t

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Why does experience matter when designing evironmental technology in die casting? <\/div><\/span>\n\t\t\t\t\t\t\t\n\t\t\t<\/path><\/svg><\/span>\n\t\t\t<\/path><\/svg><\/span>\n\t\t<\/span>\n\n\t\t\t\t\t\t<\/summary>\n\t\t\t\t
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An extraction hood can be replicated. The design behind it cannot \u2014 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 \u2014 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 \u2014 and from the experience that underpins it. <\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/details>\n\t\t\t\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t

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Kerem Kartal<\/strong><\/p>

Sales Manager +49 2244 9248 42<\/a><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t

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Your direct contact<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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Talk to Kerem Kartal<\/strong>\n<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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Would you like to know how smoke extraction, exhaust air filtration and heat recovery can be effectively combined on your die-casting machines?<\/p>

Let\u2019s 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. <\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t

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