On-Site RTO Insulation Repair

On-Site RTO Insulation Repair

A leading packaging printer had an air leak in the roof of their RTO due to insulation failure

Type of Work:
Rebuild, Repair, Retrofit
Type of Equipment:
Regenerative Thermal Oxidizer (RTO)
Flexographic Printing


A leading packaging printer had a leak in the roof of their RTO due to insulation failure. Limited downtime was the desire in order to meet this packaging printer's pressing deadlines.

Hot spots are usually due to voids/gaps in the insulation that allow hot air (1600°F+) to reach the outer wall of the RTO. Gaps can be caused by improperly installed insulation modules, damage during service work/inspection, or from air leaks through poorly gasketed flanges or weld gaps/holes.

Hot spots are not uncommon and many times are not immediate problems. However, hot spots due to air leaks can quickly progress from small issues to major problems. Most RTOs operate under a positive pressure so any air leaks will pass hot air (1500°-1660°F) to the outside and begin to weaken and degrade the metal as it passes through the hole. The metal wastes away slowly but sometimes quickly, and as the hole increases in size the rate of damage increases exponentially. Air leaks are not only dangerous to equipment health, they pose a danger to personnel from hot air leaking out at pressure.

Photos: In Progess

No items found.

Click on a picture to enlarge


Kono Kogs was contacted and provided the RTO owner counsel on stopping or delaying additional damage caused by the hot air melting the mild steel shell. Measurements were taken remotely by the customer at Kono Kogs' direction. With these dimensions and Kono Kogs extensive experience refurbishing this model of RTO (>50 units), the challenge was quickly understood and a custom designed solution was developed.

Kono Kogs was hired to remove and replace the damaged roof section and replace it with new metal. The new, pre-insulated roof was delivered, and integrated with the existing uncompromised roof metal and insulation. The fit was nearly perfect with only a few field adjustments needed. We also properly re-packed the insulation to prevent hot spots. With proper coordination this repair was completed and the RTO was operational again in under 12 hours. Kono Kogs left an extremely clean job site, and also re-started and confirmed proper RTO operation prior to leaving.

Kono Kogs has experience refurbishing nearly every major RTO model on the market, even obsolete models from OEMs that are no longer in business.

We provide every component or service related to regenerative thermal oxidizers including relocation, trade-in, field repairs, field rebuilds/upgrades, emergency service, preventive maintenance service, and replacement with our refurbished, warrantied long-life RTO systems. We have hundreds of refurbished oxidizer units installed worldwide. Why buy new when you can buy better!

Photos: After

No items found.

Click on a picture to enlarge

Equipment & Services Provided

  • Inspect RTO and assess repairs needed
  • Design & Fabricate and provide new custom roof section
  • Provide repair plan, schedule the work, & provide all materials
  • Equipment and crew
  • Thoroughly clean work site before leaving
  • Equipment re-start
Regenerative Thermal Oxidizer (RTO)

Crew finishing prep for removal of damaged roof
Interior of RTO with new roof in place
!-- Google Tag Manager (noscript) -->