Case Study: RTO VOCs Treatment System Delivery
Summary
A 3-chamber regenerative thermal oxidiser for an automotive parts supplier in Indonesia, treating 50,000 m³/h of coating-workshop exhaust at 800–1,500 mg/m³ around the clock. Double-layer ceramic honeycomb beds recover 95% of the heat so the unit sustains itself without gas above 250 mg/m³, destruction efficiency is ≥98%, and stack concentration is ≤8 mg/m³. Annual operating cost is about USD 50,000 for gas and electricity, 25% under the client's budget, as reported after commissioning in 2024.
Project Background
The client is an automotive parts supplier in Indonesia. Their new coating workshop needed a large VOCs treatment unit. They previously used another vendor's activated carbon system with high running costs.
The Challenge
The line runs 24/7 with high airflow (50,000 m³/h) and medium concentration (800-1,500 mg/m³). Lowest possible operating cost was the priority.
MUSI's Solution
MUSI recommended a 3-chamber regenerative RTO: single unit handles 50,000 m³/h, ceramic regenerator recovers 95% of heat — when concentration ≥250 mg/m³, no auxiliary fuel needed. Best operating economics.
Equipment Configuration
| Air flow | 50,000 m³/h |
|---|---|
| RTO type | 3-chamber regenerative |
| Regenerator | Ceramic honeycomb (double layer) |
| Heat recovery | 95% |
| VOCs DRE | ≥98% |
| Self-sustained | ≥250 mg/m³ |
| Fuel | Natural gas auxiliary |
| Annual operating cost | Approximately $50K USD (gas + electricity) |
Equipment used on this line
- VOCs and environmental equipment — RTO, RCO, activated carbon, zeolite rotor and wastewater treatment
Implementation
80-day delivery. The 65-ton RTO main body was shipped in 3 sections and assembled on-site — heavy lifting was the critical operation.
Results
After commissioning, emission concentration stable ≤8 mg/m³, VOCs DRE 98.5%. Annual operating cost 25% below client's original budget (originally budgeted $70K USD).
Client Feedback
"We selected MUSI based on competitive cost and proven RTO technology. After-sales response is fast — engineers reach the site within hours when needed. That's something other foreign suppliers can't match."
— Project Manager, Client Side
Selection logic: why this configuration
A regenerative thermal oxidiser was chosen over the client's previous activated-carbon system because a 24/7 line at 800–1,500 mg/m³ consumes carbon faster than it can be replaced, whereas at that concentration an RTO runs on the solvent's own heat. A single 50,000 m³/h unit with three chambers was preferred to two smaller two-chamber units because the third chamber purge keeps the outlet stable and one unit is simpler to maintain. Double-layer ceramic media was specified to reach 95% heat recovery.
Scope of supply and key components
| Item | Specification | Notes |
|---|---|---|
| RTO | 3-chamber regenerative, 50,000 m³/h | Shipped in 3 sections, 65 t |
| Heat recovery | Double-layer ceramic honeycomb, 95% | Self-sustaining above 250 mg/m³ |
| Burner | Natural gas auxiliary | |
| Controls | PLC with valve sequencing and monitoring | DRE ≥98% |
| Installation | On-site assembly and heavy lifting |
Key components
Key components are available from international brands, configurable per customer specification, so that spare parts can be sourced locally over the life of the line. Brand names below are the usual options for this type of equipment; the brands actually fitted are fixed in the contract specification.
| Component | Brands available on request |
|---|---|
| RTO ceramic media and burners | Lantec MLM, Honeywell Maxon line burners, Riello RS, Eclipse |
| Oven and dryer gas burners | Riello RS series, Weishaupt monarch WM-G, Baltur TBG, Honeywell Maxon OVENPAK, Eclipse |
| PLC and HMI | Siemens SIMATIC S7-1500, Mitsubishi Electric MELSEC iQ-R, Schneider Electric Modicon, OMRON NX, Rockwell Automation Allen-Bradley |
| Variable-frequency drives | ABB ACS580, Siemens SINAMICS G120, Danfoss VLT, Schneider Electric Altivar, Yaskawa, Mitsubishi Electric |
| Sensors and temperature controllers | SICK, Pepperl+Fuchs, OMRON E5CC, Honeywell UDC, Yokogawa UT, ifm, KEYENCE |
| Low-voltage switchgear and relays | Schneider Electric TeSys, ABB AF, Siemens SIRIUS, OMRON, Eaton |
Not included in the scope of supply
- Civil works, foundations and pits
- Building services up to the battery limit: power supply, gas, compressed air, water and drainage
- Local permits, emission approvals and third-party inspections
- Paint or powder supply, unless stated in the contract
Services included with every line: engineering design, manufacturing, shipping documentation, installation supervision, commissioning, operator training, warranty and spare parts.
Typical programme
The durations below are typical for equipment of this class and are given for planning; they are not the recorded schedule of this project. A complete line usually runs 90–180 days from contract to acceptance, a single unit 30–60 days.
| Stage | Typical duration | What happens |
|---|---|---|
| Data review and sizing | 3–7 days | Exhaust data or part drawings reviewed remotely |
| Design | 10–20 days | General arrangement and connection points |
| Manufacturing | 30–60 days | Unit built and factory tested |
| Shipping | 20–45 days | Sea freight |
| Installation and connection | 7–25 days | Ducting, gas or utilities connected on site |
| Commissioning and acceptance | 5–10 days | Performance run and acceptance record |
Results: before and after
Figures are those published on this page; measurement party, sample size, test date and method are not on record here and are left blank rather than estimated.
| Metric | Before | After | Change | Measured by | Single / average | Samples | Test date | Method / instrument |
|---|---|---|---|---|---|---|---|---|
| Stack concentration | carbon system | ≤8 mg/m³ | DRE 98.5% | |||||
| Annual operating cost | USD 70,000 budget | about USD 50,000 | −25% |
Applicability and limits
The gas-free operation above 250 mg/m³ and the USD 50,000 annual cost apply to a continuous solvent-borne exhaust at 800–1,500 mg/m³ and local energy prices. Intermittent lines or concentrations below about 300 mg/m³ usually need a concentrator or a different technology, and exhaust with silicones or halogens needs a bed material and temperature chosen for it.
Results shown in this case study reflect the stated operating conditions and should not be interpreted as guaranteed performance under different feed, production, environmental, or site conditions.
After-sales and spare parts
Warranty on a MUSI coating line runs from acceptance: 12 months on the complete line excluding consumables, 36 months on critical components such as motors, drives and the PLC, and 60 months on structural parts such as steel structure, ducting and oven bodies. Failures within warranty, excluding misuse, are repaired free of charge.
Support starts remotely: the service line is staffed around the clock, a preliminary diagnosis with recommendations is given within 2 hours, and where a site visit is needed an engineer reaches any major city within 72 hours. A spare-parts inventory is held at the Changzhou headquarters with same-day shipping, and customers can keep a dedicated parts stock at MUSI for emergencies. Details are on the after-sales service page.
FAQ
When does an RTO run without gas? Above about 250 mg/m³ inlet concentration on this unit, because 95% of the heat is recovered in the ceramic beds and the solvent supplies the rest.
What destruction efficiency does it reach? At least 98%, with the stack measured at 8 mg/m³ or below after commissioning.
How much does it cost to run? About USD 50,000 a year in gas and electricity for 50,000 m³/h, 25% under the client's original budget.
Why replace an activated-carbon system? A continuous line at 800–1,500 mg/m³ saturates carbon quickly and replacement dominated the running cost; an RTO oxidises the solvent instead of storing it.
How was a 65-tonne RTO installed? It was shipped in three sections and assembled on site; the heavy lift was the critical operation in the 80-day delivery.
Next step: a configuration proposal for a similar line
If your parts, volumes or plant conditions are close to this project, MUSI can return a line configuration and layout proposal. To prepare it we need four things:
- Photos and dimensions of the workpieces, with weight and material
- Required output (pieces per hour or per day, and shifts)
- Number of colours and how often colour changes are needed
- Available floor space and ceiling height, with the utilities on site
Message us on WhatsApp with these details, or use the quotation form.
Provided by Lin Cong, Technical Director, MUSI Technology · Published 2026-05-02 · Updated 2026-09-30 · Last technical review: 2026-09-30
QQuestions buyers ask before ordering
quotation · price · lead time · installation · warranty
What information do you need to prepare a quotation?
Send part drawings or photos, the largest part size and weight, the material, the required output per shift, the paint or powder type and number of colours, and the available floor space, ceiling height and power or gas supply. MUSI engineers reply within 24 hours; a recommended configuration and quotation follow once your part data is complete.
How much does this equipment cost?
Budget depends on part size, throughput and the level of automation. Indicative ex-works ranges are published in our complete coating line cost guide; a configured quotation is prepared from your part data. Published indicative ex-works ranges: a complete powder coating line is roughly USD 75,000–230,000 semi-automatic, USD 200,000–600,000 for a standard automatic line and USD 600,000–2,000,000 for a high-throughput automated plant.
What is the lead time?
Standard configurations ship in 30–60 days from contract signing and down payment; custom configurations take longer. The delivery date is fixed in the contract.
Do you install and train operators overseas?
Yes. MUSI engineers carry out on-site installation and commissioning and give 3–5 days of operator and maintenance training. MUSI has delivered 800+ coating lines to customers in 36 countries.
What warranty and after-sales support are included?
12 months full-machine warranty, 36 months on critical components and up to 60 months on structural parts. International customers get 24-hour phone response and 72-hour on-site arrival; spare parts ship from the Changzhou headquarters.
Can the environmental equipment be supplied with the line?
Yes. VOC treatment (RTO, RCO, activated carbon, zeolite rotor), dust collection and paint wastewater treatment are supplied with the coating line under one contract; MUSI has equipped 50+ coating facilities whose projects all passed local environmental compliance reviews.
Get a Similar Solution
If your industry and requirements match this case, contact MUSI to schedule a free consultation. We'll design an optimal solution based on your specific workpieces, capacity, and facility.