Energy-saving exhaust air solutions for injection molding machines
Innovative KMA filter systems for energy-efficient exhaust air purification and heat recovery in injection molding
In injection molding, liquefied plastic is injected under pressure into a mold. Whether toy building blocks or car body parts, injection molding is used to produce high-quality plastic components for a wide range of applications at high cycle rates and to the highest quality standards. To meet these demands, several injection molding machines are often connected in parallel. Due to the high cycle rate of the machines, large volumes of exhaust air are released into the environment at regular intervals. Cleaning this air in an energy-efficient manner and recovering valuable process waste heat is a challenge for every injection molding company. With more than 60 years of cross-industry experience, KMA Umwelttechnik is your reliable partner for customized exhaust air solutions in injection molding.
The right exhaust air purification system for your plant
Traditionally, the thermoplastic processing of plastics is accompanied by a high level of pollution of the production exhaust air. This is particularly due to the complex composition of various contaminants – in addition to particles, oily and pasty aerosols as well as vapors and mists are also released into the exhaust air. In order to reliably separate these contaminants, which can also be harmful to health, from the exhaust air and thus remove them from the working area of the employees, companies from all industries rely on the high-performance electrostatic precipitators from KMA Umwelttechnik. The separation of the KMA electrostatic precipitator is based on the principle of electrostatic charging. Inside each filter cell, an ionization electrode generates a strong electric field. Impurities in the exhaust air are electrically charged and driven to the collector plates and filter walls. Solid residues are deposited here, liquid components flow down and can be collected in an external tank. The modular design of the KMA exhaust air purification system allows a customized adaptation to the existing production conditions. Thus, the heart of the exhaust air purification system – the KMA electrostatic precipitator – can be positioned centrally or decentrally. The type of exhaust air collection can also be adapted to production conditions and customer requirements. Collection hoods and connection pieces on the machines have proven themselves in the past.
Using energy potential – thanks to innovative heat recovery
Like other casting processes, injection molding is a process that releases large amounts of thermal energy during a production cycle. Without a suitable heat recovery concept, this energy is released unused into the environment.
Comprehensive odor separation with KMA
KMA also offers its customers powerful and energy-efficient solutions for comprehensive odor separation. For this, KMA relies on its innovative UV light module. The module is part of the flexibly adaptable KMA exhaust air purification system. With the help of intensive UV light rays, odour-bearing molecules are oxidized and thus neutralized in the exhaust air flow. Depending on the individual composition of the exhaust air stream, it is led through an oxidation tunnel after the UV light module. In cases of particularly strong odour pollution, several UV light modules can also be connected in series. A combination with the KMA activated carbon filter is also possible on customer request. Thanks to the individual adaptation to the required odour load and possible customer requirements, the KMA exhaust air purification system achieves a clean air quality which meets the legal requirements for air pollution control (BImSchG, TA-Luft).
Exhaust air purification systems from KMA are suitable for the following injection molding processes, among others:
- In-Mold Process
- Source flow patterns
- Back Injection Technology
- Powder Injection Molding (PIM)
- Cascade Injection Molding
- Injection Compression Molding
- Vacuum spraying
- Extrusion injection molding (Exjection)
- Injection blow molding
- Natural fiber injection molding
- Gas injection molding (GID)
- Internal pressure injection molding (WID)
- Fusion core injection molding
- Gas back pressure process (GHD)
- Multi-component injection molding
- Thermoplastic injection molding
- Elastomer injection molding
- Thermoplastic foam molding (TSG)
- Thermoset Injection Molding
KMA ULTRAVENT® – modular und flexible
KMA ULTRAVENT® is a modular exhaust air purification system consisting of the following filter modules:
The KMA ULTRAVENT® demister cells consist of stable 50 mm thick stainless steel wire meshes, which are fixed on the inlet and outlet side by an expanded metal mesh. The special rolling of the wire enables high separation efficiency of aerosols, droplets and mists. The cells can be cleaned by washing them out. An exchange of the demister cells is not necessary.
The powerful KMA electrostatic precipitator reliably removes even the finest particles, oily and pasty aerosols, vapours or mist – without sticking or pressure loss. Each KMA electrostatic precipitator consists of numerous filter cells: Each filter cell contains an ionizer and several collector plates. The exhaust air flow passes through these cells, where it is cleaned of impurities by means of electrostatic charging. The KMA electrostatic filter is cleaned at regular intervals by the automatic filter cleaning system (CIP). Thus, no complex and cost-intensive replacement of the filter module is necessary.
The KMA modular filter system offers a wide range of mechanical filter cells for almost any application. The mechanical filter cells of KMA Umwelttechnik can be used as pre-filters (filter class G), as high-performance main filters (filter class F) and as HEPA filters (filter class H) with high separation efficiency.
For the time and energy efficient recovery of valuable thermal energy in the production process, KMA offers an integrable heat recovery system – consisting of the effective KMA heat exchanger of the powerful KMA Abitherm® heat pump. The combination can be individually tailored to the application and customer requirements. The recovered energy can then be fed back into the product cycle or used for other purposes. The KMA heat recovery system is part of the KMA exhaust air purification system and is therefore also cleaned at regular intervals by the automatic filter cleaning system (CIP).
The KMA UV light module is an important part of the KMA strategy for odour separation. With the help of photo-oxidation, a clearly perceptible improvement of the odour in the exhaust air stream is detected. Depending on the degree of pollution, complete odor separation can be achieved.
As part of the KMA exhaust air purification system, the KMA UV light module follows the KMA electrostatic precipitator, as this is the only way to ensure a comprehensive separation result. In addition, a reaction section is connected downstream of the UV light module.
In addition to the KMA UV light module, KMA also relies on the KMA activated carbon filter for the separation of odorous vapors, mists or aerosols. The odour-bearing molecules are deposited on the porous surface of the activated carbon and are thus removed from the exhaust air flow. Like the KMA UV light module, the KMA activated carbon filter is preceded by the KMA electrostatic precipitator for particle separation. Thus, a high degree of separation is achieved.
For a comprehensive separation of odorous aerosols, gases, vapors or mist, KMA uses its innovative KMA exhaust gas scrubber. This works according to the absorption principle, with the help of a suitable washing liquid the impurities are bound and separated. Combined with the KMA electrostatic precipitator or the mechanical filter from KMA, the KMA exhaust gas scrubber achieves a high separation efficiency with a low water consumption.
KMA’s automatic filter cleaning system CIP (cleaning in place) is one of the main reasons for the long service life of KMA exhaust air purification systems. In addition to the KMA Electrostatic Filter, the automatic KMA filter cleaning system also reliably cleans the KMA UV light module or the KMA heat exchanger from impurities and residues.