Process Air

A stable production process starts with stable process conditions. When air is a direct part of the production process, temperature, humidity, air purity and airflow must remain under control at all times.

Callens Group develops process air systems that monitor and control these conditions accurately. This helps you guarantee consistent product quality, prevent unwanted variations in the production process and increase the reliability of your installation.

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When are industrial air technologies for process air important?

When air is an essential part of the production process, it must meet specific requirements. Industrial air technologies ensure that temperature, humidity, air purity and airflow are controlled accurately, so the required process conditions are maintained, and consistent product quality is guaranteed.

Depending on the application, process air is dried, humidified or filtered. The techniques used depend entirely on the requirements of the production process and the desired product quality.

A well-designed process air system provides consistent production conditions, higher product quality and a more stable production process. At the same time, it helps reduce rejects, use energy more efficiently and increase installation reliability.

 

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Typical challenges where an air technology solution for process air adds value:

  • Drying products in a controlled manner without quality loss or longer process times.
  • Guaranteeing constant humidity during production, storage or packaging processes.
  • Removing dust, microparticles or other contaminants from the air that could affect product quality.
  • Creating reproducible process conditions, regardless of weather conditions or seasonal influences.
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Process air for industrial applications

Callens Group develops air technology solutions for industrial production environments where air is a direct part of the production process and where temperature, humidity and air purity have a direct impact on the quality of the end product.

Process air systems are typically integrated into process lines in sectors such as food, pharmaceuticals, chemicals, paper and cardboard, textiles, plastics processing and other industries.

As with all our projects, we start with a thorough analysis of your specific situation. We then take care of the entire process as an EPCS integrator, including service and maintenance. In short, with Callens Group you get a single partner who develops a process air system from A to Z, perfectly aligned with your production environment.

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Solutions

Our process air system solutions

Our process air systems include various techniques to condition air in a controlled manner in accordance with your production process. Depending on the application, we combine several techniques into one integrated system that is fully tailored to the required process parameters.

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Industrial air dehumidification

Excess moisture can have a negative impact on products, processes and machinery. Air drying keeps humidity under control and prevents condensation, quality loss and production problems.

More about industrial air dehumidification
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Industrial air humidification

Air that is too dry can cause products to dry out, trigger electrostatic discharge or create process instability. Controlled air humidification keeps relative humidity within the required limits.

More about industrial air humidification
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Industrial air filtration and purification

Dust, microparticles and other contaminants can negatively affect product quality and process reliability. Air filtration removes these unwanted particles and creates controlled process air.

More about industrial air filtration and purification

Always close to customers with 13 locations Local support backed by group expertise.

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THE CALLENS GROUP IN NUMBERS

One partner. 60 years of expertise. Complete peace of mind.

With Callens Group, one partner handles the entire process: from concept engineering to installation, including service and maintenance. This integrated approach combines technical expertise, project experience and a strong service organization.

+500 projects per year

Broad experience across a wide range of industrial applications.

Service and support within 2 hours

Fast assistance when continuity matters.

+400 qualified team members

A strong team of specialists across disciplines.

60 years of experience in EPCS projects

Proven expertise in integrated industrial projects.

Always close to customers with 13 locations

Local support backed by group expertise.

Technology-independent advice

Advice based on your process and business needs.

How do industrial air technologies for process air contribute to a more sustainable production environment?

Process air can be a major energy consumer in industrial production processes. Drying, humidifying, filtering or conditioning air means process air installations use energy continuously. So, a well-considered design can make a real difference to your company’s energy consumption and operating costs.

Callens Group develops process air systems that combine maximum process control with a minimal environmental footprint. By intelligently combining energy-efficient technologies, heat recovery and precise controls, we create sustainable solutions that contribute to a more efficient production process.

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Heat recovery

In many process air installations, heat is lost through extracted air or process flows. By recovering this energy and reusing it within the production process or for other heat consumers, you reduce your site’s primary energy consumption.

Energy efficiency

Not every production process requires the same amount of treated air at every moment. That is why we accurately align airflow rates, fans, control technology and process parameters with the actual demand. This ensures that only the energy needed to guarantee the required process conditions is used.

Less product loss, higher yield

Stable process air quality prevents quality deviations, rejects, and unnecessary waste of raw materials. By continuously controlling temperature, humidity and air purity, you increase the reliability of your production process and use raw materials, energy and production resources more efficiently.

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A well-considered air technology concept starts at your site

Drawings and technical data sheets tell only part of the story. That is why Callens Group always looks beyond theoretical calculations or third-party studies.

Our engineers start each project with a thorough analysis of the production environment. During an on-site visit, we map all the factors that influence the process air, such as temperature, humidity, air purity, airflow rates, heat and moisture loads and the interaction between different production processes. We also analyze how process air is used and which process conditions are needed to guarantee consistent product quality.

Based on these measurements and practical insights, we develop a correctly sized process air concept that is fully tailored to your production process. This gives you an air technology solution that performs optimally in day-to-day operations.

Working with Callens Group means peace of mind, reliability and certainty

A process air system is an investment that helps determine the success of your production process for years. That is why it is best to choose a partner that designs the right air technology solution and provides the service needed to guarantee lasting performance. You will find that combination at Callens Group.

From the initial analysis to installation, commissioning, and ongoing maintenance, the Callens Group takes care of your air technology project from start to finish. During every phase of the project, you have a contact person with the right technical expertise. This ensures smooth coordination, short communication lines, and efficient execution.

Callens Group is not tied to one brand, manufacturer, or technology. The advantage is that we can start from your production environment and specific challenges rather than from a standard solution. That is why our engineers start every project with a thorough on-site analysis. During this site visit, we map all the factors that influence air management, such as airflows, heat sources, moisture load, air flow rates, pressure differences, and the interaction between the different production processes. Based on these measurements, we develop a correctly dimensioned air technology concept that best suits your situation, both technically and economically.

Even after installation, you can continue to rely on the Callens Group. Together with specialist partners, we provide maintenance and service so your air technology installation keeps performing reliably. This increases operational reliability, extends the service life of the installation, and reduces unplanned downtime.

The Department of Technology is the innovation center of the Callens Group. Here, new developments in air technologies are assessed for their technical feasibility and added value in industrial applications. Only proven technologies ultimately make their way to our customers.

With 13 locations across Belgium, the Netherlands, and France, we combine the advantages of an international group with the proximity of local teams. This allows us to be on the ball, to respond quickly, and to support our customers long-term.

Local presence, international strength

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Air technology Process air Cleaning

Air handling unit exudes safety

Capacity160.000 m3/h 
Air velocity0,4m/s
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Air technology Drying Process air +2

Dehumidification with additional air conditioning and heat recovery

Extraction flow 4 x 28,000 m3
Supply air flow 4 x 28,000 m3
Heating capacity4 x 224 kW
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Air technology Process air Drying

Excellent ventilation for excellent fries

Capacity2 x 120,000 m3/h
Residual heat1,600 kW

Projects with industrial process air

A well-designed process air installation treats only the air that is truly needed and aligns airflow rates, fans and control technology with the current process demand. In addition, in every project Callens Group investigates how heat from process air or extracted air can be recovered as much as possible and reused within the production process. This lowers energy consumption and operating costs in your production environment.

Condensation occurs when warm, humid air comes into contact with colder surfaces or when humidity becomes too high. This can lead to corrosion, microbiological growth, quality loss, longer drying times or unwanted production downtime. Callens Group prevents condensation by looking at temperature, humidity, airflow rates and airflows as one integrated whole. During an on-site technical analysis, our engineers map all the factors that influence condensation risks. Based on this, we develop a process air system that continuously monitors the required process conditions and automatically makes the necessary adjustments. This keeps your production process stable, guarantees product quality and reduces the risk of rejects. Not sure whether your process air installation is optimally aligned with your production process? Our experts will be happy to analyze your situation and develop a tailored process air solution. Contact us.

A conventional HVAC system is designed to create a pleasant and healthy indoor climate for people. With process air, the focus is different: temperature, humidity, air purity and airflow must remain within precise limits at all times to guarantee a stable production process and consistent product quality. This requires an air technology solution that is fully tailored to the specific requirements of your production process. That is why Callens Group starts from a thorough analysis of your process, the required process conditions and the interaction between people, machines and the production environment. Based on this analysis, we develop a correctly sized process air system that is technically and economically aligned with your application. Curious what a process air solution for your production process could look like? Our experts will be happy to think along with you.

The required capacity depends on several factors, such as the desired temperature and humidity, airflow rate, heat and moisture load of the process and the characteristics of the building. Production capacity, operating hours and possible future expansions also play a role. Thanks to practical measurements and simulations, the Callens Group engineers calculate the capacity needed to guarantee the required process conditions in an energy-efficient way.

Correct sizing starts with a thorough analysis of your production process. During a visit to your site, our engineers map temperature, humidity, airflow rates, heat and moisture loads, dust load and the interaction between different process steps. We not only consider the required process conditions, but also the working conditions of the operators who work with the installations every day. Desired product quality, production capacity and future expansions are also included. Based on practical measurements, we develop a technical concept that is fully tailored to your production process and your people. This ensures an installation that performs optimally without being over or undersized.

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