At Amcor (formerly Berry BPI), an old afterburner sits on the roof, which no longer meets current emission and energy requirements. In the preliminary phase, CERVITECH BV conducted a production study and combined this with future plans.

This research was the starting point of the final project. This project not only consists of supplying the new Regenerative Thermal Oxidizer (RTO), also called an afterburner, but also of optimizing the production equipment, designing the assembly of production machines, piping, valves and the RTO and putting the entire assembly into production.

Phase 1

A blueprint of the factory is created through various flow and concentration measurements on various product machines, which are linked to the old RTO. Based on these measurements, an accurate picture of the current situation is recorded.

Phase 2

This phase involves developing a plan to improve the process values as measured in Phase 1. In addition to making this plan, it will also be implemented. By executing, a new blueprint is created with new values for both flow and concentration.

Phase 3

Determine what the capacity of the new RTO will be with the input of parameters and the values that were previously determined. In this phase, the complete project plan has been developed in terms of project matters and schedules.

Phase 4

In deze fase begint de realisatie van het projectplan tot aan de daadwerkelijke plaatsing van de nieuwe RTO. Zo komt er een nieuw fundament op het dak zodat de nieuwe RTO daarop kan worden geplaatst. De oude klepmotoren worden vervangen door fail-safe motoren. Deze heeft Cervitech ook geleverd.

Phase 5

Installing and fully connecting the RTO to the foundation on the roof.

Phase 6

The RTO was started entirely by CERVITECH BV. In December 2023 there were no connections to production and production could therefore continue. On January 8 and 9, the new pipework from the by-pass valves to the new RTO was installed. The entire communication from production to the new RTO was carried out by CERVITECH BV. Production could be started again on January 9 and the entire transition went according to plan.

The delivery also includes measuring the sizes of remaining VOCs in the air after cleaning the RTO. The legislation prescribes a maximum value of 100mg/Nm3. The new RTO even remained below < 10mg/Nm3.

Next step: connecting to new flexo printing press

A maintenance contract has also been signed with Amcor. Following the successful installation of the RTO, the next step in production development is planned. A new flexo printing press will be installed soon. CERVITECH will manage the entire process for connecting it to the existing RTO system.

The work includes the supply and installation of the pipework, the realisation of the electrical connections and the commissioning of both the pressure press connection and the associated systems.

With this expansion, the increased production capacity remains fully integrated into the existing emission control system, ensuring that the installation meets current environmental requirements.

This project was developed in collaboration with RELOX and HOLTROP & JANSMA. The start date was March 1, 2023.
Thanks to the new RTO, the environmental benefit is that clean air is created in the area.