Dürr and Orafol Elevate Sustainability with Advanced Oxi.X RE System for Next-Generation Production Hall

Dürr and Orafol Elevate Sustainability with Advanced Oxi.X RE System for Next-Generation Production Hall

(IN BRIEF) Dürr Systems AG and Orafol Europe have deepened their long-standing partnership with the installation of a new Oxi.X RE regenerative thermal oxidation system at Orafol’s 14,000 m² production hall in Oranienburg, Germany. Part of a 160 million euro investment in expanding its production capabilities, Orafol is upgrading its facility for laminating and coating special films and adhesive tapes. The innovative RTO system, integrated as a turnkey project, purifies solvent-laden exhaust air by oxidizing organic compounds at high temperatures while recovering over 96% of the energy through its advanced ceramic heat exchanger. This technology not only cuts energy costs but also enhances environmental performance by reducing carbon emissions. The new system, featuring a sophisticated energy management module to ensure optimal thermal balance, is Orafol’s largest installation to date and highlights the company’s commitment to sustainable production. Dürr plans to further expand this technology as part of Orafol’s ongoing production hall expansion.

(PRESS RELEASE) BIETIGHEIM-BISSINGEN, 2-Apr-2025 — /EuropaWire/ — In a further testament to their enduring collaboration, Dürr Systems AG and Orafol Europe have taken another step forward in sustainable production technology. On April 2, 2025, in Bietigheim-Bissingen, it was announced that Orafol Group will install a state-of-the-art regenerative thermal oxidation (RTO) system—its latest Oxi.X RE model—in the new 14,000 m² production hall at its Oranienburg facility in Germany. This new facility, dedicated to laminating and coating special films and adhesive tape systems, is part of Orafol’s record-setting 160 million euro investment in expanding production and adopting cutting-edge, energy-efficient environmental technology.

Orafol, renowned for its expertise in producing self-adhesive graphical products, reflective materials, and industrial adhesive tapes, is responding to increasing global demand by modernizing its infrastructure. The new Oxi.X RE system has been chosen for its ability to oxidize nearly all organic compounds in solvent-laden exhaust air at temperatures between 800°C and 900°C. Thanks to its integrated regenerative heat exchanger—featuring advanced ceramic honeycomb bodies that store and transfer heat with remarkable efficiency—the system preheats incoming exhaust air to nearly 800°C using energy recovered from previously treated air. This process, which operates autothermally without supplemental fuel even at low solvent loads, recovers over 96% of the required energy, significantly reducing both operational costs and environmental impact by lowering Orafol’s carbon footprint.

The turnkey RTO project, which encompassed everything from design and production to installation and commissioning, also included comprehensive integration of associated piping, ductwork, and a boiler for converting surplus heat into process steam. Orafol, which already runs thirteen air pollution control systems across its 280,000 m² headquarters (including nine Oxi.X RE systems from Dürr), benefits from a long-standing partnership with Dürr. Marcel Janßen, Senior Vice President of Engineering & Technology at Orafol, highlighted that this collaboration has consistently delivered tailored solutions that exceed regulatory standards for air purification while ensuring energy recovery is both efficient and productive.

A key innovation in the new installation is its advanced energy management system. Comprising two specialized modules—XtraBalance, which equalizes temperature disparities among the three RTO chambers, and XtraControl, which maintains an optimal average temperature via continuous sensor monitoring—the system guarantees reliable operation and maximizes the conversion of waste heat into usable energy. This robust setup not only enhances operational reliability and resilience under fluctuating conditions but also sets a new benchmark for energy efficiency in industrial air pollution control.

Looking ahead, Dürr is already planning an additional Oxi.X RE system to further optimize exhaust air purification for Orafol’s expanding coating systems. This continued innovation reinforces the strong, adaptive partnership between Dürr and Orafol, driving sustainable development and operational excellence in high-performance production environments.

Media Contact:

Kristin Roth
Marketing
kristin.roth@durr.com

SOURCE: Dürr Systems AG