{"id":27643,"date":"2026-06-09T14:14:52","date_gmt":"2026-06-09T12:14:52","guid":{"rendered":"https:\/\/www.kma-filter.de\/industries-applications\/exhaust-air-filtration-and-heat-recovery-for-the-foundry\/"},"modified":"2026-10-30T13:47:08","modified_gmt":"2026-10-30T12:47:08","slug":"exhaust-air-filtration-and-heat-recovery-for-the-foundry","status":"publish","type":"page","link":"https:\/\/www.kma-filter.de\/en\/industries-applications\/exhaust-air-filtration-and-heat-recovery-for-the-foundry\/","title":{"rendered":"Exhaust air filtration and heat recovery for the foundry"},"content":{"rendered":"\t\t
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Exhaust air filtration\nand
heat recovery<\/b>
for the foundry<\/h1>\t\t\t\t<\/div>\n\t\t\t\t
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Clean air, smart use of process waste heat and noticeably improved energy efficiency in the foundry \u2014 thanks to foundry-proven exhaust air technology and holistic production hall ventilation systems.<\/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\tPOTENTIALS<\/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\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 example<\/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\tFAQ<\/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\tContact<\/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\t<\/div>\n\t\t\t\t<\/div>\n\t\t
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\n\t\t\t\t\tYour potential for foundries<\/span>\t\t\t\t<\/div>\n\t\t\t\t
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The green competitive advantage for your foundry<\/h2>\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\t\t\t\t\t\"Potential-Metall-DE-Web\"\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t
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We are your foundry experts for emissions, waste heat and energy. <\/strong><\/p>

Every foundry is a continuous process. Metal becomes product. Energy becomes emissions and waste heat. That is exactly where your savings potential lies. <\/p>

KMA sees the foundry as a whole: we combine exhaust air filtration, heat recovery, supply air and production hall heating into one system instead of individual components.<\/p>

Systems that reliably eliminate emissions while running efficiently. The focus is on your foundry’s waste heat as an energy source. Instead of venting it unused, we recover the energy and send it where it is needed \u2014 to hall heating, the paint shop and more. <\/p>

\u2713 Increase energy efficiency<\/strong><\/p>

\u2713 Meet emission requirements<\/strong><\/p>

\u2713 Improve ESG rating<\/strong><\/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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We put our trust in KMA<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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\"DGS
<\/div><\/figure><\/div>
\"GF
<\/div><\/figure><\/div>
\"Harting
<\/div><\/figure><\/div>
\"BMW
<\/div><\/figure><\/div>
\"IDRA
<\/div><\/figure><\/div>
\"Volvo
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\"DAIHATSU
<\/div><\/figure><\/div>
\"VW
<\/div><\/figure><\/div>
\"Magna
<\/div><\/figure><\/div>
\"Nemak
<\/div><\/figure><\/div>
\"B\u00fchler
<\/div><\/figure><\/div>
\"DAIMLER
<\/div><\/figure><\/div>
\"Renault
<\/div><\/figure><\/div>
\"VOIT
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Solutions for the energy-efficient foundry\n<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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Where in the foundry can we support you?<\/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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\n\t\t\t\t\n\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\tSmoke extraction & exhaust air filtration
die casting<\/strong>\t\t\t\t\t<\/span>\n\t\t\t\t\n\t\t\t\t\n\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t\t<\/a>\n\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\n\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\tHeat recovery & exhaust air filtration
melting furnace<\/strong>\t\t\t\t\t<\/span>\n\t\t\t\t\n\t\t\t\t\n\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t\t<\/a>\n\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\n\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\tIntegrated solutions
Megacasting<\/strong>\t\t\t\t\t<\/span>\n\t\t\t\t\n\t\t\t\t\n\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t\t<\/a>\n\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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\n\t\t\t\t\n\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\tIntegrated ventilation solutions for production halls<\/strong>\t\t\t\t\t<\/span>\n\t\t\t\t\n\t\t\t\t\n\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t\t<\/a>\n\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\n\t\t\t\t\t\t\t\t\t\n\t\t\t\t\t\tSmoke extraction
CNC machining<\/strong>\t\t\t\t\t<\/span>\n\t\t\t\t\n\t\t\t\t\n\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\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\t\t\t\t\t\"\"\t\t\t\t\t\t\t\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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From \"nice to have\"\nto a relevant decision criterion\n<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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Which foundry would you choose?<\/h2>\t\t\t\t<\/div>\n\t\t
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Foundry of yesterday: dark, dusty, dangerous<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t

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Foundry of today: bright, clean, energy-efficient<\/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

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\n\t\t\t\t\t\t\n\t\t\t\t\t\t\tIncreased
wear
on machinery\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<\/div>\n\t\t
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\n\t\t\t\t\n\t\t\t\t<\/path><\/svg>\t\t\t\t<\/span>\n\t\t\t<\/div>\n\t\t\t\n\t\t\t\t\t\t
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\n\t\t\t\t\t\t\n\t\t\t\t\t\t\tContamination of equipment
and production halls\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<\/div>\n\t\t
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\n\t\t\t\t\n\t\t\t\t<\/path><\/svg>\t\t\t\t<\/span>\n\t\t\t<\/div>\n\t\t\t\n\t\t\t\t\t\t
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\n\t\t\t\t\t\t\n\t\t\t\t\t\t\tRisk
of regulatory penalties\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<\/div>\n\t\t
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\n\t\t\t\t\n\t\t\t\t<\/path><\/svg>\t\t\t\t<\/span>\n\t\t\t<\/div>\n\t\t\t\n\t\t\t\t\t\t
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\n\t\t\t\t\t\t\n\t\t\t\t\t\t\tRisk to
workplace safety\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<\/div>\n\t\t
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\n\t\t\t\t\n\t\t\t\t<\/path><\/svg>\t\t\t\t<\/span>\n\t\t\t<\/div>\n\t\t\t\n\t\t\t\t\t\t
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\n\t\t\t\t\t\t\n\t\t\t\t\t\t\tCertification
for end customers\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<\/div>\n\t\t
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\n\t\t\t\t\n\t\t\t\t<\/path><\/svg>\t\t\t\t<\/span>\n\t\t\t<\/div>\n\t\t\t\n\t\t\t\t\t\t
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\n\t\t\t\t\t\t\n\t\t\t\t\t\t\tValue retention
for investments\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<\/div>\n\t\t
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\n\t\t\t\t\t\t\n\t\t\t\t\t\t\tQuality management
requirements\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<\/div>\n\t\t
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\n\t\t\t\t\t\t\n\t\t\t\t\t\t\tSecuring
skilled workers\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<\/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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Good evironmental technology is not created in-house alone. We have a research partnership with the Center for Lightweight Casting and Design (GTK) at the University of Kassel on the energy-efficient capture of emissions at die casting machines. In a joint project funded by the German Federal Environmental Foundation, we are investigating air curtain systems as an alternative to ever larger Extraction hoods \u2014 for machines from 400 t to over 5,000 t clamping force, as used in megacasting. <\/p>

KMA contributes experience from plant engineering, while GTK provides the scientific analysis and its own machinery for practical testing. In addition, we participate in the industry\u2019s expert committees, including the Federal Association of the German Foundry Industry, and share our results at specialist events such as the Global Giga Casting Congress in Kassel. <\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t

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Cooperations with foundry chairs and associations<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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Research & development<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t
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CUSTOMER EXAMPLE energy-efficient foundry<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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Benefit like the STIHL magnesium die casting plant<\/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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“Our system is proof that sustainable production becomes concretely measurable: less CO\u2082, highly efficient use of existing process heat, and independence from fossil fuels in production hall heating.”<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t

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Hartmut Fischer, Managing Director, ANDREAS STIHL AG & Co. KGMagnesium Die Casting Plant<\/p>\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\tHow STIHL uses its recovered process heat<\/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\t<\/div>\n\t\t\t\t<\/div>\n\t\t
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The trade publication GIESSEREI published the project in Weinsheim as \u201cBest Practice: High-performance heat recovery\u201d.<\/a> Download the complete case study now and find out why this efficiency project is receiving special attention in the industry.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t

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Holistic air management
Best practice at STIHL<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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Download<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t
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Improved energy efficiency for foundries\n<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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70% of your energy costs are in process heat. We recover it. <\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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Integrated solutions for the foundry combine exhaust air cleaning, heat recovery, supply air and energy reuse in one coordinated system. Exhaust air is not just cleaned and released. The process heat it carries is put to use. This makes your plant more energy efficient. <\/p>\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\n\t\t\t\t<\/path><\/svg>\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\tHere\u2019s the link to the dena guide for foundries (German language)<\/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
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At home in foundries all over the world.<\/h2>\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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We are the specialists for foundry-proven solutions around exhaust air filtration and heat recovery.<\/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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Frequently asked questions about exhaust air filtration\nin the foundry<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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Why should a foundry consider exhaust air filtration and heat recovery together? <\/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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Process exhaust air contains both emissions and usable heat. If both are considered together, the exhaust air is cleaned and its energy is fed back into operations instead of escaping unused through the roof. This can also be implemented retrospectively in existing foundries: heat recovery is integrated into existing extraction and supply air systems. For new systems, it is planned in from the start. KMA brings exhaust air filtration, heat recovery, supply air and energy utilisation together in a coordinated overall system. <\/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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Why should a foundry recover heat if it already has too much of it? <\/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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Because it\u2019s not about heat, it\u2019s about energy recovery, energy recuperation: every kilowatt-hour you recover is one you don\u2019t have to buy. You have already paid in full for the energy in your exhaust air via gas or electricity \u2014 unused, it leaves the plant through the roof. Once recovered, it replaces purchased energy and immediately reduces energy costs, operating costs and CO\u2082 emissions. How quickly the investment pays for itself is determined by three factors: the energy source being replaced, the operating hours and the CO\u2082 price. <\/p><\/div>\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 can the recovered energy from the process exhaust air be used for? <\/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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For virtually all heat sinks at the site: production hall heating, supply air heating, service water, burner air preheating at the melting furnace, or adjacent processes such as the paint shop. In principle, feeding into a district heating network, absorption cooling or power generation via an ORC system are also possible. Which sink is the right one is determined by two factors: the temperature level of the exhaust air and the time overlap between heat supply and heat demand. From our foundry projects, we know the typical sinks and their special features \u2014 so we advise you not only on the recovery itself, but on the most sensible utilisation in operations. <\/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 requirements does my foundry need to meet for exhaust air filtration with heat recovery? <\/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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No special requirements. Every foundry is different, which is why we design every system to suit the on-site conditions. Key factors are the number and size of the die casting machines, the production hall geometry, the existing ventilation technology, the available installation space on the roof or floor, and the heat sinks in operations. Existing supply air systems are integrated and not replaced, as in the STIHL magnesium die casting plant, where the existing layer ventilation was fully incorporated into the new solution. What\u2019s possible at your site, we clarify on location based on your real production hall and process situation. <\/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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How can I improve air quality in my foundry? <\/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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The most effective approach is smoke extraction directly at the die casting machine. What escapes into the production hall spreads throughout the entire volume and requires a higher air exchange rate \u2014 with corresponding energy input and risk for occupational safety requirements for production hall ventilation. Alternatively or additionally, central capture in the production hall roof is possible, as implemented at STIHL. We know the foundry-specific solutions for air pollution control (APC) and design them to match your machine layout and production hall situation. <\/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 a central exhaust air filter system and when a decentralised one? <\/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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Decentralised \u2014 one filter per machine \u2014 is recommended for distributed emission sources and growing production, because long exhaust air ducting is eliminated and the system grows with each new machine. Central \u2014 multiple machines on one filter station \u2014 scores with a lower investment per cubic metre of volume flow rate in dense machine layouts, but requires more complex piping. The deciding factors are the production hall layout, number of machines, expansion plans and the heat utilisation concept. Based on your production hall layout, we will propose the right configuration for you. <\/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 exhaust air filtration, heat recovery, supply air management and production hall heating can be sensibly combined in your foundry?<\/p>

Then let’s work together to find the system concept that fits your site technically and energetically. The basis is always your real hall and process situation. <\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t

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