A WELSH coatings manufacturer has installed an online gas analysis system to monitor emissions of Volatile Organic Compounds (VOCs), using real-time data to improve environmental performance and support regulatory compliance.

ProAmpac Advanced Coatings (PAC) invested in a new Regenerative Thermal Oxidiser (RTO) in 2025. As a Part A2 installation, the Wrexham site has long operated an on‑site thermal oxidiser to protect the environment and meet the requirements of an environmental permit issued by the local council.  

The RTO destroys VOCs, air pollutants and odours through high‑temperature oxidation and is continuously monitored using a Signal Group VOC analyser to optimise performance and provide early warnings of any issues. "We see the analyser as essential," said Dan Hitchcock, project manager at PAC. "Real‑time data supports effective process control and allows us to verify that emissions are being correctly abated. That gives us confidence that we will meet emissions limits when regulatory testing is carried out."

Investing ahead of regulatory change

Installed in 1995, the original RTO was approaching the end of its service life after 30 years of continuous operation, with ageing ceramic beds requiring increasing maintenance. At the same time, emissions regulations affecting solvent‑based coating processes were becoming more stringent. Updates to the Best Available Technique (BAT) Reference Document for Surface Treatment using Organic Solvents (STS BREF) introduced lower emission limits for applicable installations, prompting the local council to begin drafting a revised permit for the site.

"In that context, relying solely on periodic testing would not give us the level of operational visibility we need," Hitchcock explained. "Continuous monitoring allows us to manage performance proactively rather than retrospectively." With an ageing RTO, and with the prospect of tighter regulations, PAC chose to install a new, more efficient RTO with a capacity of up to 150,000 Nm³/hour, commissioned in 2025.

Real‑time data, real‑world benefits

Following more than 20 years of reliable service from its first Signal Group analyser, PAC selected Signal once again when upgrading its monitoring system for the new RTO. The original instrument has been replaced with an MCERTS‑approved SOLAR CEMNEX continuous FID analyser, installed at the base of the RTO exhaust stack.  The company also supplied the heated sample line.  As an MCERTS‑certified system, the analyser’s data are accepted by regulators including Natural Resources Wales and the Environment Agency.

PAC continues to operate continuous VOC monitoring alongside statutory compliance testing. An integrated monitoring and alarm system provides management staff with real‑time displays, historical data and automated alerts.  The system also confirms correct operation and calibration of both the analyser and the heated sample line.

"Continuous VOC monitoring allows us to identify potential problems early and address them before they escalate," said Sean O’Brien, the site’s health, safety and environment manager. "It gives us confidence that compliance monitoring will demonstrate performance that meets permit requirements, while providing additional reassurance to the regulator."

For more information: 

signal-group.com

Tel: +44 (0) 1276 682 841