ESTA PROJECT COMPETENCE
PROCESS AIR TECHNOLOGY
EXTRACTION SYSTEMS FOR YOUR PRODUCTION
For over 25 years, ESTA has been your expert supplier of process air technology systems for industry. Whether for new construction projects or retrofits: ESTA's customised extraction concepts are precisely tailored to your production processes and spatial conditions.
Thanks to their modular design, our filter systems can be expanded at any time and adapted flexibly to new requirements.
ESTA's central extraction systems and workshop ventilation systems keep the air clean and ensure compliance with the legal limit values for workplace emissions. Thanks to intelligent control systems, integrated heat recovery and fire and explosion protection, the systems are energy efficient and operate economically and safely.
Our experts will guide and support you from planning to commissioning, ensuring a consistently reliable result.
YOUR CONTACT FOR EFFICIENT PROCESS TECHNOLOGY
“For over 20 years, my team and I have been supporting our customers in process air technology – not only on a project basis, but as a long-term partner.
Whether it's a new installation or retrofitting complex plant systems, my priority is to create sustainable, high quality solutions that you can rely on for many years to come. Trust, continuity, and technical due diligence are central to my approach.”
Philipp Reisser
Head of Sales, Projects Segment
YOUR BENEFITS AS A PROJECT PARTNER
- Energy-efficient complete solutions including, for example, control concepts and heat recovery.
- Low operating costs thanks to durable, cleanable filter elements
- Modular design allows for later system expansions.
- Low operating noise thanks to sound insulation
- Optionally available in an ATEX-compliant version for potentially explosive atmospheres
- Short delivery and assembly times
Comprehensive after-sales service
360° PROJECT COMPETENCE
From the initial consultation through to planning and manufacturing, assembly,
commissioning, and maintenance – our experienced project managers will guide you step by step through the successful implementation of your process air technology system.
LEARN MORE ABOUT OUR 360° SERVICE
PROCESS AIR TECHNOLOGY
CENTRAL SYSTEM CONCEPTS
Customised extraction systems for individual applications
The key to the effectiveness of an extraction system is an optimal design tailored to specific requirements. At the company headquarters in Senden, engineers use state-of-the-art software to create detailed 3D drawings, such as workshop plans with integrated extraction systems or flow simulations. For specialist applications, process engineering solutions are developed in our in-house technical centre.
We also handle interface management and ensure the seamless integration of the extraction system into the machining or production process.
FUTHER INFORMATION ON THE DESIGN OF A PROCESS AIR ENGINEERING SYSTEM
WORKSHOP VENTILATION SYSTEMS
Minimising pollutants & increasing energy efficiency
Localised extraction directly at the source of the pollutants remains the most effective method of capturing them almost completely.
In practice, however, local extraction systems are often only of limited use depending on the application and working environment – for example, in the case of changing work and welding positions, oversized workpieces or workstations that are situated far apart from one another.
Push-pull mixed ventilation
upstream stratified ventilation
ESTA offers customised workshop ventilation systems that are ideally suited for combination with existing extraction solutions. These systems reduce pollutant levels over a large area and are particularly indispensable in spacious production environments.
Depending on the design, they can be installed as a standalone central extraction system or to supplement direct extraction systems.
PROCESS AIR TECHNOLOGY SYSTEMS WITH HEAT RECOVERY
Recover energy, permanently reduce costs.
With integrated heat recovery, your extraction system will not only be more environmentally friendly, but also significantly more economical.
The exhaust air cleaned by the PLT systems is fed into the HVAC system. Modern heat exchangers make efficient use of the energy contained in the exhaust air, regulate room temperatures, and reduce energy consumption.
The systems are flexible in their application – for both cooling and heating – and can be adapted to different process requirements.
WHAT MATTERS IN PRACTICE
QUIET, BUT POWERFUL.
This keeps the noise level in your production shop low – without compromising performance.
Sound-optimised system technology pays dividends in noise-sensitive areas (for example, assembly or final inspection). Energy-efficient filter technology not only saves energy costs, but also secures long-term competitive advantages.
Modern ESTA control systems with sophisticated sensor technology ensure precise control of the extraction systems, while frequency converters enable demand-controlled fan output. An intelligent summer / winter switch further contributes to reducing energy costs.
SAFETY FOR EXPLOSIVE AREAS.
In industrial areas where flammable dusts or gases are present, an explosion-proof system in accordance with the ATEX directive is essential.
ESTA offers ATEX-compliant systems that are precisely tailored to your industry-specific requirements.
Our solutions include pressure shock resistant filter housings, check valves, explosion pressure relief devices and spark extinguishing systems – all from a single source, tested and certified.
LEARN MORE ABOUT THE ESTA FIRE AND EXPLOSION PROTECTION CONCEPT
REDUCE ENERGY COSTS, SECURE COMPETITIVE ADVANTAGES.
Energy-efficient filter technology not only saves energy costs, but also secures long-term competitive advantages.
Modern ESTA control systems with sophisticated sensor technology ensure precise control of the extraction systems, while frequency converters enable demand-controlled fan output. An intelligent summer / winter switch further contributes to reducing energy costs.
Impressions of process air technology
INDUSTRY-SPECIFIC
THE RIGHT SOLUTION FOR EVERY INDUSTRY
ESTA offers customised extraction systems for virtually all industries and areas of application.
The focus is on the following key industries:
| Industry | Areas of application |
|---|---|
| Metalworking | Welding, grinding, turning, milling, laser, flame and plasma cutting |
| Solar and wind energy | Milling, grinding, deburring, polishing, sawing, drilling |
| Recycling | Crushing, shredding, separating, screening, sorting, pressing, cleaning |
| Food and animal feed | Pneumatic conveying, mixing, screening, decanting, dosing, cleaning |
| Chemistry and pharmaceuticals | Mixing, dosing, filling, screening, drying, coating, tableting, cleaning, pneumatic conveying, dusting, grinding, packaging |
| Medical technology | Drilling, milling, polishing, grinding, deburring, ultrasonic welding, laser processing, surface treatment, dust extraction, plastics processing |
| Vehicle construction | Grinding, welding, bonding, casting, painting, pressing, plastics processing, chip extraction, laser cutting |
| Aviation | Grinding, drilling, milling, polishing, composite material machining (e. g. CFRP / GFRP), bonding, deburring, painting, chip extraction , fine dust extraction, composite dust extraction |
| Paper, cardboard and goods | Cutting, punching, bonding, laminating, embossing, folding, printing, disposal of stamping grids, edge strip extraction, pneumatic conveying |
Customer feedback
Thomas Lechner
Production Control Production system Rosenberger Hochfrequenztechnik GmbH & Co. KG„The robust high-vacuum extraction system with cyclone pre-separator is designed for outdoor installation and can reliably handle even large quantities of chips. Discharge into big bags works flawlessly – a well-thought-out and durable solution, perfectly implemented from planning to implementation.“
Rainer Körner
Manager Industrial Engineering, SAF-Holland GmbH„Competence, reliability and professional project management have been a feature of our partnership. Our Bessenbach location has a number of different extraction systems which are all tailor-made to the particular application concerned. The basis for this is the modular ESTA machine principle.“
Stefan Hartl
workshop foreman Pfaffinger Anlagenbau & Energietechnik GmbH„The two extraction systems fit perfectly into our two new halls. In line with Pfaffinger's 361-degree principle, “Always be one degree better”, we want to set standards not only for our customers, but also for our employees as an employer. This includes, in particular, the issue of occupational safety.“
Manfred Zahn
Plant planning, PERI GmbH„We take our duty of care towards our employees very seriously. With our new extraction system, it is our very conscious aim to undersell the legal requirements.“
Alexander Wiens
Head of mechanical manufacturer, BBS GmbH„A contact form completed on the ESTA website got things going. Two days later, a sales representative and an engineer came to our company. After a precise look at process-specific matters, ESTA staff were able to offer us some initial proposed solutions. The extensive know-how of ESTA employees and the speed with which they worked through or request have convinced us.“
Lothar Lehnbaur
Works manager, Kettlitz-Chemie GmbH & Co. KG„In our production facility, we have equipped a number of work processes with ESTA extraction technology. From industrial extractors to mini dust collectors to large dust removal systems - all devices and plants have been in use for many years and work perfectly. The large range of products including accessories and spare parts and decades of experience in all issues to do with extraction make ESTA an indispensable partner in this area as far as we are concerned.“
Timo Kukec
Head of maintenance, SAF-Holland„ESTA coordinated the planning and arrangement our our extraction system in a very detailed and precise manner. It was important for us that a single contact person accompanied us for the whole duration of the project. ESTA employees worked through everything quickly and effectively from consultancy services to assembly. Process integration was also done to our complete satisfaction.“
Thomas Traub
Facility Services Electrics, Catalent Germany Schorndorf GmbH„I have only had good experience with the ESTA Service team. A call is usually enough and employees were able to provide me with some basic tips and instructions over the phone. Service employees regularly come to our company to maintain the machines. In this way we assure the long-term operation of the system.“
Randy Koch
Head of production, KWD Automobiltechnik GmbH„We have been using ESTA extraction systems for many years at our plants. These systems run in multi-shift mode and reliably extract fume gases from our welding systems. The extraction systems must always be adapted to the production line due to the processes involved. This was easy to do and was always done quickly.“
Raphael Miehling
subject teacher, Berufsschule Eichstätt„In autumn, our trainees can look forward to a state-of-the-art, well-equipped training workshop that is also unrivalled in terms of occupational safety. We are very proud of this unique selling point in our training programme.“
PRACTICAL EXAMPLES
- Plant engineering - Pfaffinger Anlagenbau & Energietechnik GmbH, Iggensbach
- Commercial vehicle supplier - SAF-Holland GmbH, Bessenbach
- Construction industry - Peri GmbH, Weißenhorn
- Automotive supplier and defence industry - Rheinmetall AG, Düsseldorf
- Vehicle construction - BBS GmbH, Osnabrück
- Ernst Wirth GmbH & Co. KG
- Schmidt + Bartl GmbH
- Rosenberger
- LINHARDT Viechtach GmbH & Co.KG
- Staatliche Berufsschule Eichstätt
- HUBER SE
- AVT Verpatec AG (Schweiz)
WOULD YOU LIKE TO LEARN MORE?
COOPERATION WITH PLANNING OFFICES AND TECHNICAL BUILDING SYSTEMS PLANNERS
We have been working succesfully with technical building systems planners, architects and general planners for many years. We offer customised extraction solutions that are perfectly tailored to your customers' production processes, spatial conditions, and energy requirements.
Our process air technology concepts combine efficiency, safety and convenience, while simultaneously ensuring the highest standards in terms of sustainability and operating costs.
Even before the project is awarded, we are at your side with free consulting and planning services to ensure a smooth process and a solid foundation for your project.
Our services include, among other things, on-site visits to analyse the conditions, the creation of tender documents and CAD data, as well as the preparation of technical documentation.
CONTACT
WE ARE HAPPY TO PROVIDE A PERSONAL CONSULTATION
We can adapt our exhaust installations to your needs. Tailor-made, modular and individual. Ask us!
Frequently Asked Questions (FAQ)
HVAC systems (heating, ventilation and air conditioning systems) are primarily used for general room ventilation, while process exhaust air systems are specifically designed for capturing, filtering, and discharging industrial emissions. Both systems can be combined to create a comprehensive ventilation system.
An industrial extraction system is part of process air technology. It captures dust, fumes, or vapours directly at the source and removes the contaminated exhaust air through filter modules. The aim is to ensure air quality in production shops, while simultaneously increasing the energy efficiency of manufacturing.
The replacement interval depends on the system load. ESTA uses high quality, cleanable filter elements that are automatically cleaned during operation. This significantly extends filter service life and reduces operating costs.
When filter cleaning is no longer possible, ultrasonic filter cleaning ensures that even heavily soiled filter cartridges can be thoroughly cleaned and reused – instead of being replaced.
VDI 6022 prescribes regular inspections and cleaning to ensure hygiene, fire protection, and operational safety. Industrial process air technology often requires shorter maintenance intervals because the exhaust air is significantly more contaminated with dust or gases.
In heat recovery, the energy from the cleaned process exhaust air is used to preheat fresh air. This allows an exhaust air ventilation system to reduce heating energy requirements by up to 40 % – a decisive factor for cost-effectiveness.
Modular systems in process air technology allow for a precisely tailored system design. The combination of energy-efficient system components, intelligent control and heat recovery permanently reduces the costs of the ventilation system.
A clean process exhaust system prevents the build-up of flammable dust deposits or aerosols. Regular cleaning reduces the risk of fire and explosion and increases the service life of the entire extraction and ventilation system.
The heat energy recovered from the process exhaust air is fed into an HVAC system. This creates a highly efficient exhaust air ventilation system that filters emissions and simultaneously reduces the heating or cooling energy required for the production shop. This solution combines sustainability, energy efficiency, and occupational safety.
An ATEX-compliant extraction system is always mandatory if explosive atmospheres can occur in a production shop – for example, due to flammable dusts, gases, or vapours. According to ATEX Directive 2014/34/EU, all technical components in potentially explosive areas must be designed so that they do not constitute an ignition source.
ESTA supplies pressure shock resistant filter housings, check valves, explosion pressure relief devices and spark extinguishing systems that comply with applicable safety standards and are certified.
In Germany, companies can apply for government subsidies for the installation of energy-efficient ventilation systems in industrial buildings. The Federal Office for Economic Affairs and Export Control (BAFA) and the KfW Development Bank offer grants and low-interest loans for investments in energy-efficient ventilation and process air technology.
Depending on the programme, up to 45 % of eligible investment costs may be covered. Further information and current programmes can be found within the framework of the Federal Funding for Efficient Buildings (BEG).
Yes, retrofitting is possible in most cases without any problems. Modular system concepts and flexible piping systems allow central extraction systems to be integrated even into existing workshop structures.
ESTA offers customised planning for this purpose, taking into account the existing workshop architecture, production processes and energy efficiency requirements – for an optimal solution without long downtimes.
- Workshop ventilation: Ensures air exchange throughout the entire production workshop. It supplies fresh air, regulates the air temperature (heating / cooling), and ensures comfortable working conditions.
- Central extraction: Captures emissions directly at the source, e. g., dust, fumes or vapours, and filters them from the exhaust air before they enter the environment.
The combination of both systems – workshop ventilation for the indoor climate and central extraction for clean air at the workplace – creates a holistic ventilation solution with maximum energy efficiency and occupational safety.
