Printing and packaging – efficient exhaust air treatment and reliable solvent reduction

Why is exhaust gas treatment so important in printing?

Modern printing processes such as flexographic, offset and gravure printing, as well as packaging production, rely heavily on solvents and printing inks. These inevitably evaporate during the drying processes.

As a result, considerable quantities of volatile organic compounds (VOCs) are released into the exhaust air. To protect the environment and employees and to reliably meet strict statutory requirements (such as the TA Luft), these emissions must be reliably filtered and neutralised.

A tailored catalytic exhaust air treatment system offers an efficient and space-saving solution here.

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Challenge: VOC emissions and solvent vapours

The drying and curing phases in printing plants produce a highly concentrated exhaust gas stream. Typical pollutants include:

Toluene
Ethyl acetate
Ethanol and alcohols
Other volatile organic compounds (VOCs)

Without effective catalytic oxidation, these vapours not only pose a serious health and safety risk but also exceed the strict statutory emission limits. In addition, fluctuating solvent concentrations require a highly flexible treatment system.

Produktionshalle mit Maschinen für die Verpackungsherstellung

The role of catalysts in the printing process

Catalysts are integrated into the exhaust air stream and chemically convert harmful solvent vapours at comparatively low temperatures. Compared with purely thermal oxidation, this saves a considerable amount of energy:

VOCs + O₂ → CO₂ + H₂O

Specific advantages for printing and packaging

Compliance with the TA Luft

Reliable and lasting compliance with the statutory emission limits for printing plants.

Toluene and ethyl acetate decomposition

Highly efficient reduction of specific and critical printing ink solvents.

Space-saving installation

Thanks to the compact design, well suited for retrofit in existing printing halls.

Energy-efficient operation

Lower operating temperatures conserve resources and noticeably reduce your energy costs.

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Background knowledge

Frequently asked questions

Answers on technology, legislation and processes in printing and packaging.

Which industries need catalytic treatment of solvent vapours?2026-10-15T13:08:53+02:00

Which industries need catalytic treatment of solvent vapours?

Catalytic exhaust air treatment is required or economically sensible in all industries that release volatile organic compounds (VOCs). These include industrial painting and coating lines, the chemical industry, printing and packaging companies (flexographic and gravure printing), woodworking (gluing and drying) and the plastics processing industry. Treating the exhaust air protects the environment and prevents odour nuisance in the neighbourhood.

What is a solvent management plan under the 31st BImSchV?2026-10-15T13:08:53+02:00

What is a solvent management plan under the 31st BImSchV?

The 31st BImSchV regulates emissions of volatile organic compounds from installations that use solvents, for example in printing, painting or packaging production. Operators covered by the regulation must document their solvent flows in a solvent management plan, also known as a solvent balance. It compares the solvents fed into the installation with where they end up: in the product, in waste, in the captured and treated exhaust air or as fugitive emissions via room air and windows. The authority uses this balance as evidence that the requirements of the regulation are being met. Catalytic exhaust air treatment has a direct effect on this balance, as it reduces the share of captured solvents that actually reach the environment. The better the capture at the machines, the lower the fugitive share. If you provide your current solvent management plan and details of your exhaust air ducting, we can assess the contribution that exhaust air treatment can make.

How is exhaust air from flexographic and gravure printing presses prepared for a catalyst?2026-10-15T13:08:53+02:00

How is exhaust air from flexographic and gravure printing presses prepared for a catalyst?

In printing presses, solvents are released at several points: at inking units, dryers, laminating units and into the hall air. Targeted capture at the sources is important for economical catalytic treatment, because the higher the solvent concentration in the exhaust air, the less additional energy the catalyst requires. A common approach is recirculation in the dryers, where part of the dryer air is returned and the concentration increases as a result. For large flow rates with low concentrations, upstream concentration, for example with an adsorption wheel, can make sense. For safety reasons, the concentration must always remain well below the lower explosive limit, which is monitored by measuring equipment. Changing print jobs and downtime at individual presses also influence the design. Send us the number and type of presses, the solvents used and any existing exhaust air measurements, and we will check how your exhaust air can be captured and treated effectively.

About Pure Air GmbH

Experience in exhaust gas treatment

Pure Air GmbH is built on many years of experience in catalytic exhaust gas treatment. Since 2025 we have brought this know-how together in Bamberg: we design catalysts for your plant, supply them and support them in operation, from CHP units to industrial installations.

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Engineer designing an exhaust gas treatment system on a CAD workstation

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Pure Air GmbH
Am Börstig 12
96052 Bamberg

office@pure-air.gmbh

+49 (0) 951 96433250
+49 (0) 170 9630471