Comfort and safety: Blauberg system in a printing house in Szeged

The world of flexographic printing is particularly sensitive to air quality. The fumes from inks and solvents, thermal load, and humidity peaks not only affect the comfort of workers but also the operational reliability of the equipment and the quality of production. Therefore, at the Poli-Union Zrt. printing house in Szeged, two, Blauberg heat recovery air handlers have been implemented in a modern ventilation and air conditioning system: BlauAIR BL15 (≈10,000 m³/h) and BlauAIR BL45 (≈48,000 m³/h). The larger capacity BL45 maintains stable air exchange and a uniform flow pattern even during peak times when multiple printing machines are running simultaneously, while the BL15 is optimized for serving smaller zones, preparation areas, and accompanying functions. The system connected to cooling thus creates a comfortable modern technologies operationally reliable environment.

Why is printing air technology critical?

In a printing environment, three factors dominate the design of air technology: heat, a steam/odor and the solid or liquid aerosol (oil and ink mist) presence. Together, these factors influence not only employee comfort but also the reliability of equipment, reproducible color retention, and the rate of defects. If thermal load is not under control, viscosity and drying profiles fluctuate; if odors and vapors „leak” from the technological zone, the olfactory footprint appearing in the guest area or warehouse poses a reputational risk. heat recovery (HRV) and in today's energy costs, it is not a luxury: it provides a balanced climate and measurable operational savings.

The key in this project was that the large-volume printing hall receives continuous, even air exchange, along with local exhausts and inflows, all of this draft-free modern technologies at low noise levels.. The Blauberg „quiet-tuned” aerodynamics (optimized impeller, laminated air duct, modern heat exchanger geometry) played a significant role in this: with the same air volume, lower pressure drops can be achieved, resulting in lower RPM and less noise entering the space.

The solution: BlauAIR BL15 + BL45 – capacity and reserve

With the two different sized air handlers, the printing house can be zoned : in the large hall section, the BL45 provides the „backbone,” while the BL15 ensures targeted supply in the smaller areas. capacity reserve in practice means that there is no „dense air” or warm bubble even during peak times, and during shutdown, the system demand-driven reduces (with EC fan speed control). The two devices work in coordination with the cooling circuit: the fresh air is tempered, enters evenly, thus there are no cold or warm fronts in the work area.

The HRV core is particularly striking in the cold-warm season: the winter fresh air preheating and the summer precooling occurs through heat exchange, thus the cooling/heating mechanical part is less burdened. The decreasing peak demand and smoother partial load operation energy and noise gain at the same time.

Safety and hygiene: grease pre-treatment, condensation and filtration strategy

In flexo operation, the air technology's „safety belt” is the proper filtration and pre-treatment. It is advisable to design a filter and condensation treatment strategy for both the intake and exhaust sides that protects the heat exchanger and prevents deposits in the ducts. The implementation emphasized:

• Filter stage: pre-filtering for larger particles, finer stage for protecting the heat exchanger – both with quick, tool-free replacement.
• Condensation treatment: planned slopes, collection and drainage, to prevent both dripping and corrosion.

These steps are not only for hygiene but also acoustic are valuable from a perspective: there is less pressure drop on a clean filter, the fan operates at a lower speed can run, the system remains quieter. The cleanability is inherently served by the design – accessible cleaning openings, smooth-walled pipes, large radius bends.

Flow pattern and comfort: draft-free supply, even mixing

The bane of large air volume halls is the uneven distribution. If the supply is too fast or arrives at the wrong angle, workers feel cold at the edges, are warm in the center, and the sensation of draft appears. In the current project, on the supply side with plenum boxes modern technologies we refined to low exit speed with tuned grids: the air distributes „like a carpet” and mixes quickly. The extraction works where the contamination is generated – thus concentrates locally modern technologies relieves globally.

On the comfort side, alongside silence, the odor neutrality and the stable temperature profile were the two greatest gains. According to employee feedback, the space feels „lighter” and 1. odor-neutral, 2. , even in long shifts with „sustainable” climate.

3. Control technology and monitoring: demand-driven operation safety

4. The soul of the system is the 5. presence-/temperature-/CO₂-based 6. regulation. Adapting to the pace of the machines, the fans' speed 7. scales smoothly, 8. , there is no „rev-up–shutdown” cyclicality. The fault signals (filter pressure difference, fan anomaly, condensate level) are sent to the monitoring system, so the operation 9. is proactive10. : by the time comfort deteriorates, the maintenance technician already knows what to do.

11. This mindset – the 12. data-driven 13. operation – reduces costs in the long run. The air volumes adjusted to the actual load require less electrical energy, extend the lifespan of filters and moving parts, and 14. maintain a stable noise level. 15. Filtration and condensate treatment in an industrial environment.

Results in practice

After the project handover, the most important feedback was organized around three points. On one hand, consistent quality: due to the stability of the climate, there is less parameter fluctuation in the technology. On the other hand, employee comfort: quieter space, better well-being, less feeling of fatigue at the end of the shift. Thirdly, operational reliability: maintenance is more predictable through monitoring and alerts, and there are fewer unexpected shutdowns.

It is also valuable for Poli-Union Zrt. that the system can be expanded and fine-tuned in the future – if the machinery changes, the airflow patterns and air volumes can be adjusted, and the zones can be optimized independently.

What can an industrial plant learn from this?

Whether a printing house, food industry hall, or assembly plant, the lessons are generalizable. The order leading to success:

1. Separation and pre-treatment at the source – protection of the duct and heat exchanger, cleanable design.
2. Draft-free, large surface inflow – low exit speed, good mixing.
3. Demand-driven, data-based control – quiet at partial load, reserve at peak.

These three pillars together provide 7. also provide comfort – lower draft sensation, better mixing, more even temperature., energy awareness modern technologies safety.

Related solutions and next steps

If you are designing heat recovery ventilation for an industrial space, it is worth considering a zonable concept thinking: connect large air spaces to a backbone network, provide targeted injection above workstations, and extract at the point of pollution generation. The demand-driven control (CO₂/temperature/presence) ensures that the system only operates when and where justified. More and more plants are examining this line of thought during renovations, especially if they want to achieve energy savings and comfort improvements simultaneously.

The case of Poli-Union Zrt. in Szeged clearly shows that industrial comfort and safety are not mutually exclusive factors when the ventilation is based on heat recovery modern technologies demand-driven aerodynamics is built. The BlauAIR BL15 modern technologies BL45 air handlers provide a uniform climate, stable air exchange, and favorable operation – tailored to the needs of printing technology. The recipe is straightforward: pre-treat at the source, inject slowly over a large surface, control based on data. The end result: cleaner air, quieter space, and more predictable operation.

Would you like similar, quiet, and energy-efficient industrial ventilation? Contact us and request an on-site survey + preliminary technical concept: vents.hu/contact. Based on your needs, we will provide a proposal for capacity, heat exchanger type, filtration and noise reduction strategies, as well as control – so that the ventilation remains in the background and production is in the foreground.