Energy efficiency is vitally important for him –and for your company

Your contribution to climateprotection: Improve the eco-logical footprint of your foodmanufacturing processes

The carbon footprint is still a relatively new term inthe context of global environmental discussions. It is defined by the total amount of carbon dioxide(CO2) emissions caused by production processes. Industrialised countries have committed themselvesto reduce their CO2 emissions by at least 20 percentby the year 2020.

The consequence: in all areas of our society large efforts are being made in order to prepare new lawsand regulations. But alongside discussions concer-ning electric cars or energy-saving light bulbs seenin the media, many other profound changes are occurring in silence: in a wide range of industries,entire production processes are being modified orreplaced by more energy-efficient technologies.

This change is posing a challenge for all companies:whoever ignores this development, is taking the riskof being shut out of the market, as avoidable CO2-emissions can cause higher additional costs. Henceit is time to question one’s own production facilities.

The KMA AAIRMAXX® filter system for the food pro-cessing industry does not only remove smoke andbad odour from the air, it additionally – thanks to an energy-saving operation – reduces CO2-emissionssignificantly. Consequently KMA AAIRMAXX® wasawarded with acknowledged innovation prizes suchas the DLG FoodTec Award.

Energy consumption and CO2-emissionsgenerated by production processes areexamined in the course of all discussionrelated to climate change. The modularKMA AAIRMAXX® air filtration system reduces the amount of power necessaryto clean the air by up to 80 percent. Andpreserves the environment.

Energy consumption and CO2-emissionsgenerated by production processes areexamined in the course of all discussionrelated to climate change. The modularKMA AAIRMAXX® air filtration system reduces the amount of power necessaryto clean the air by up to 80 percent. Andpreserves the environment.

The most important factor for industrial environmentalprotection: efficiency

KMA waste air filtration systems can be applied tomany fields within the processing industry. Duringthe course of development our engineers and processtechnicians consistently focus on sustainability andenergy efficiency. As a result, the KMA waste air fil-tration system consumes up to 80 percent less energyin comparison to conventional post-combustion systems!

Lowered energy consumption equals: lower costs!Consequently a KMA waste air filtration system ispaid off in a relatively short time due to the reducedenergy costs.

KMA Umwelttechnik stands for quality and innova-tion. More than 2500 filter systems worldwide pro-vide evidence of this. Their use achieves sustainedsuccess by avoiding environmental pollution such assmoke and odour. At the same time they make an important contribution to climate protection due tominimum energy consumption.

The most important areas of application are:� Frying facilities / continuous frying systems

� All areas of application for smoking meat or fish

� Baking facilities and baking ovens

� Roasting plants for coffee / cacao / nuts

� Large-scale catering establishments, canning factories

� Livestock breeding and fattening facilities

The Greek letter Eta (�) in Physics symbolises the

effectiveness and degree of efficiency for the utilisation

of energy. Efficient environmental

protection in any industry is the consistently used synergetic

effect between the maximum degree of efficiency and the

minimal energy input. AAIRMAXX® waste air clean up

is effective and efficient in environmental protection!

The degree of efficiency is crucial!

The modules of the KMA AAIRMAXX® air filtration systems:

Many production processes in the food industry cause a waste air composite made ofsmoke and impurities resulting in odour. The six energy-saving modules of the AAIRMAXX®air filtration system provide a solution to any problem created by waste air in the food processing industry.

Activated Lignite FilterActivated Carbon and Lignite are oftenconsidered to be a universal remedy forthe removal of odour at food processingfactories. Odorous substances and airmolecules settle on the surface of theActivated Lignite. For a cost-effectiveoperation it is necessary to have an effective pre-treatment of waste air as well as the right dimensioning welladapted to each case of operation. Therefore the range of application islarge.

BiofiltrationThe Biofilter from the AAIRMAXX®

modular system is designed to removeodour and gas of a low concentrationfrom large volumes of waste air. Theoperation of a Biofilter is particularlycost-effective in the case of constantwaste air flow.

Air Cooling, Heat RecoveryIn the case of cleaning waste air of ahigh temperature (> 40° C) and high humidity the AAIRMAXX® air cooler can be used in the conditioning stage, in particular for Biofilters and Activated Lignite filters. Waste air vertically passesthrough a heat exchanger made ofstainless steel tubes. Separated oil,grease, and water are then dischargedby a condensate drain. Heat recovery in the form of hot processing water can be achieved in combination with a KMA Ambitherm heat pump.

Electrostatic precipitators for the separation of smokeand dustThe AAIRMAXX® particle filter effecti-vely separates aerosols such as grease,tar (smoke), or oil from waste air with-out clogging. It is made of one or seve-ral metal tubes with an ionisator in themiddle of each tube. The particles arecharged by electrostatic energy andsettle on the inner surface of the tubes.The cleaning process of the filter takesplace automatically and at regular intervals.

Waste Air ScrubberThe scrubber is designed for the sepa-ration of odour, gas, and fumes, andoperates according to the absorptionprinciple. The gases and fumes contai-ned in the waste air are first capturedand then separated by the use of anappropriate washing liquid. Further-more the scrubber can be applied as a humidifier before waste air entersinto the biological filter.

UV Light OxidationMalodorous VOC molecules (e. g. from frying processes or large-scale kitchens) can be oxidised by means of UV light. The result is a considerablereduction in odour, and in many casesodour eliminated altogether.

The modular KMA AAIRMAXX® air filtrationsystem can be used for all applications inthe food processing industry.

Tunnel Frying Units

Ham Smokehouse

This smokehouse facility with more than 20 smokingchambers was equipped with a central KMA AAIR-MAXX® filter system which consisted of an electro-static filter for the removal of smoke and tar as wellas a waste air scrubber. The filter has a modular design and is cleaned by an integrated automatic CIP cleaning system.

Protecting the environment:saving energy as well as costs.No problem with a KMA wasteair filtration system

Two KMA AAIRMAXX® filter systems were installed topurify the waste air (grease, smoke, odour) of severaltunnel frying units with an overall waste air volumeof 12 000 m³/h. The filter system consists of air-to-airheat exchangers, scrubbers, and biofilters. The systemwas mounted on the rooftop, directly above fryingunits.

Production facility for fish food

Fish food production processes cause highly malodorous waste air. In order to avoid annoyanceto neighbouring residences waste air is being purified by an AAIRMAXX® air filtration system.The filter system consists of a waste air scrubberand an activated lignite filter. The pH level con-trol and the water exchange take place auto-matically. The activated lignite filter is composedof two separate towers providing a capacity of 12 500 m³/h each.

Hot Dog production line

The production process of hot dogs on a smoking and scalding continuous line creates a large load ofsmoke and odour. Initially a thermal post-combustionsystem was used for this application, however due to high operating costs and enormous CO2 emissionsthis system was replaced by a KMA AAIRMAXX®

smoke filtration system, providing a capacity of 1 500 m³/h. The annual energy cost savings thereforeadd up to more than 60 000 Euro; leading to the annual reduction of greenhouse gas emissions bymore then 200 t!

AAIRMAXX® filters purifywaste air while saving energyand CO2!This is active environmentalprotection which pays off.

In the food processing industry the largest potentialto avoid CO2 emissions, apart from refrigeration tech-nology, lies within waste air filtration technology.Conventional catalytic or thermal post-combustionsystems require large amounts of oil, gas, or electri-city for waste air purification. High energy consump-tion is therefore accompanied by a correspondingamount of CO2 emissions.

For example: a thermal post-combustion systems providing a capacity of 1 500 m³/h (corresponding approximately to a smokehouse with 6-8 smokingchambers) requires more than 50 m³ of natural gas,even when used in combination with a modern heatrecovery system. This is not only costly, but leads toCO2 emissions equating to approximately 100 kgevery hour. The consequence: even if the annual use is only 1 500 hours (equivalent to approximately 6 hours of smoking per day) an operator will face

an energy consumption of more than 50 000 m³ ofnatural gas. While simultaneously generating a CO2

burden of approximately 100 tons! This is where anenormous potential for cost and CO2 savings lies formany smoke houses and frying facilities:

By replacing an old air treatment device with anenergy-saving AAIRMAXX® filter system energy consumption is decreased by around 80 percent. This is accompanied by a considerable reduction of CO2

emissions. In the example mentioned above, the re-sult is an annual reduction of CO2 emissions by over80 tonnes! The expenditure for a new filter systemwill therefore be amortised in less than 3 years.

Replace your post-combustion systemnow and save money!

Ask us for a free operation cost compari-son adapted to your specific application.AAIRMAXX® waste air filtration systemspurify the air and reduce your consump-tion of natural gas at the same time!

You will save energy, reduce the consump-tion of our resources, and preserve theclimate. This is active climate protection!

Compact and energy efficient:The smoke filtration system KMA AX 750 purifies the waste air of up to 6 smoking chambers

ETNV

KMA

The advantages of AAIRMAXX® waste air filtration systems at a glance

KMA AAIRMAXX® fits to any production process!Whether you are roasting, frying, baking, smoking, or drying. With the KMA AAIRMAXX® air filtration sys-tem it is possible to deal with any waste air problem,while staying flexible with your production processes.

Refurbishing an old plant with KMA AAIRMAXX®

KMA waste air filtration systems have zero negativeimpact on processes taking place during production.Existing production plants are able to continue opera-tion without modifying their original design and willin turn meet the requirements of the TA-Luft* regula-tions. The advantage: established food products canremain the same in relation to their manufacturingtechniques and sensation of taste kept 100 percentidentical.

The operating costs of a KMA AAIRMAXX®-waste air filtration system are considerably lowKMA waste air filtration systems use the most advan-ced, as well as the most cost-effective method forwaste air clean up by combining both the techniquesof electrostatic precipitators as well as gas scrubbers.In comparison to conventional methods of post-combustion, energy costs are decreased by up to 80 percent.

High filtration efficiencyKMA AAIRMAXX® waste air filtration systems ensurecompliance with the emission limit values accordingto the TA-Luft* regulations and the VDI** directives.

Operation almost free from wearKMA AAIRMAXX® waste air filtration systems are notvulnerable to thermal wear. More than 2 500 systemsinstalled in numerous manufacturing works, andsome with over 50 000 hours of operation, serve asevidence of this.

* German TA-Luft are the Technical Instructions on Air Quality Control** Association of German Engineers

* German Federal Immission Control Act

What remains to be said

The company KMA is characterised by people who,above all, are convinced that producing energy-effi-cient air purification systems makes an active contribu-tion to the continued protection of the environment.

We hope that we have been able to give you some valuable information in terms of energy-efficient solutions for waste air and odour issues in the foodprocessing industry.

We would be happy to work out a configuration proposal - free of charge of course – with a sample appliance which would be adapted to your exact requirements. By means of a comprehensive systemdescription and a detailed operating cost comparisonwe can then find the most economically favourablesolution to meet your needs.

Our range of services comprises:

� Consulting, design, tender

� BImSchG* applications

� A supply of complete air purification systems

� Service

Call us, send us a message, or visit ourwebsite. We look forward to your enquiry.

EN ISO9001:2000

CertifiedCompany

KMA Umwelttechnik GmbH Eduard-Rhein Straße 2 53639 Königswinter GermanyPhone: +49 2244 9248 - 0Fax: +49 2244 9248 - 30 info@kma-filter.dewww.kma-filter.de

F I L T E R