Gas Analysis System Continuous VOC Monitoring Delivers Operational and Environmental Benefits

A leading coatings manufacturer in Wales has installed an advanced online gas analysis system to monitor emissions of Volatile Organic Compounds (VOCs), enabling the company to leverage real-time data for measurable environmental, operational and compliance benefits.

Proampac Advanced Coatings, which has operated on the Wrexham Industrial Estate for more than 50 years, invested in a new Regenerative Thermal Oxidizer (RTO) in 2025. The RTO destroys VOCs, air pollutants and odors through high‑temperature oxidation and is continuously monitored using a Signal Group VOC analyzer to optimize performance, provide early warnings and support regulatory compliance.

The company finds the analyzer as essential. Real‑time data supports effective process control and allows the firm to verify that emissions are being correctly abated. That gives the company the confidence that it will meet emissions limits when regulatory testing is carried out.

Long‑standing commitment to emissions control

Proampac Advanced Coatings (PAC) is a global supplier of precision coating materials, including coated papers, films and specialist substrates for applications such as digital imaging, electronics, medical and optical technologies. Its manufacturing processes involve the use of solvents, making robust emissions control essential.

As a Part A2 installation, the Wrexham site has long operated an on‑site thermal oxidizer to protect the environment and meet the requirements of an environmental permit issued by the local council. Historically, the permit has included emission limit values (ELVs) for pollutants such as Total Organic Carbon (VOCs), carbon monoxide and nitrogen oxides. These emissions are checked during annual visits by an Mcerts‑accredited contractor.

In addition to periodic compliance testing, PAC has continuously monitored post‑combustion VOC emissions for over 20 years using a Signal Group analyzer employing a flame ionization detector (FID), the reference method for VOC measurement. The original analyzer remained in operation for approximately two decades.

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 the company the level of operational visibility that it needs, explains the firm. Continuous monitoring allows the company 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

PAC continues to operate continuous VOC monitoring alongside statutory compliance testing. The firm shares that real‑time data is critical to effective control of both coating processes and the RTO. The analyzer helps the firm to optimize oxidizer performance, manage emissions from the coating lines, and control fuel input. Any issue with the RTO could have serious consequences, so early detection is vital, mentions the company.

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 analyzer and the heated sample line, adds the firm.

According to the company, continuous VOC monitoring allows it to identify potential problems early and address them before they escalate. It gives the firm confidence that compliance monitoring will demonstrate performance that meets permit requirements, while providing additional reassurance to the regulator.

Proven performance from Signal Group

Following more than 20 years of reliable service from its first Signal Group analyzer, 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 analyzer, installed at the base of the RTO exhaust stack. Signal Group also supplied the heated sample line. As an Mcerts‑certified system, the analyzer’s data are accepted by regulators including local councils, Natural Resources Wales, Sepa and the Environment Agency.

The system is supported by daily automatic zero checks, periodic span checks using calibration gas, and comprehensive on‑site servicing every six months under a long‑term maintenance agreement with Signal Group.

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