Maximize your system’s performance and extend its lifespan with our comprehensive ceramic media services, including expert bake-outs and hassle-free turnkey replacements. Over time, media can become plugged or fouled, leading to reduced efficiency and potential system failures. We help you stay ahead of costly downtime by ensuring your media is clean, properly matched, and optimized for your specific needs. As an independent partner — not tied to any OEM — we provide objective recommendations tailored to deliver the best performance and value for your operation.
A well-executed ceramic media replacement can lower operating costs and extend media life. The key? Understanding your RTO’s design, airflow, VOC load, and compliance needs to choose the right media for cost-effective performance.
The condition of your Regenerative Thermal Oxidizer’s (RTO) ceramic media plays a critical role in overall system efficiency. Our full range of ceramic media services ensure your system operates at peak performance — supporting consistent production, reducing energy costs, and helping you stay in compliance with your air permit. Our media services include:
Your RTO’s ceramic saddles and tower packing can become plugged or damaged over time, reaching a point where bake-outs no longer restore performance. When this happens, the ceramic media must be replaced to re-establish your RTO’s full flow-rate capacity and utilization.
Our experienced field-service staff will analyze your system and application, identify your issues, select the appropriate high-quality replacement ceramic media optimized for your needs and perform a thorough ceramic media replacement from start to finish, including help with media disposal and system start-up.
Let’s talk. When it comes to the performance and efficiency of your RTO, the type of ceramic media you choose plays a big role. Our technical experts can help you evaluate which product is most appropriate for your specific RTO and application, meeting your needs for thermal efficiency, pressure drop, particulates, ROI, particulate load, and more. As an unbiased third party (unlike an OEM), we can offer you a qualified judgment as to the benefits and drawbacks of different types of media.
Call us for an expert evaluation and recommendation. If a media change is necessary, we can work around your scheduling needs and provide a turnkey solution – from removal of the faulty media to the supply and installation of new media optimized for your system design and exhaust airstream.
A metal container manufacturer operating a 40,000 SCFM Regenerative Thermal Oxidizer (RTO) was facing serious operational challenges. High system pressure drop, temperature imbalances, and frequent media bake-outs were disrupting production and raising concerns about passing an upcoming air compliance test. Read how we delivered a turnkey solution—resolving system inefficiencies, restoring flow balance, and reducing downtime.
A recycling facility that processes waste bakery products experienced significant reductions in airflow capacity, negatively impacting production rates. The bottleneck was a two-chamber RTO (Regenerative Thermal Oxidizer) system that had prolonged startup times, suffered significant chamber temperature imbalances, and contained ineffective ceramic media.
Read how we successfully completed two different media changes and other RTO repairs in suddenly challenging conditions, on time and on budget.
If you’re unsure, it may be time to reassess your ceramic media selection to optimize performance, reduce maintenance, and extend RTO life.
Often, we conduct larger repairs to the system concurrent with a media change. We can also perform media changes when the ceramic media is already on hand.
On the other hand, random packed ceramic media—like saddles or rings—are loose-fill shapes poured into the chamber. While it’s a more budget-friendly option up front, it tends to have higher pressure drop and slower heat recovery, which can lead to increased energy consumption and less consistent performance over time.
Bottom line: While structured media may require a larger investment upfront, it can be a better choice for long-term efficiency and reliability. However, the type of media you choose must be right for your RTO, application and needs for ROI. Want help choosing the best media for your RTO? Let’s talk.
Facilities Engineering Manager, Fortune 100 Auto Manufacturer (and PolSys Service Agreement customer)
How do you know when it’s time for new ceramic media in your RTO? Learn six important telltale signs that a ceramic media change should be considered.
RTO ceramic media comes in two main types—random packed (like saddles) and structured (e.g., monoliths, corrugated, and MLM)—each offering unique benefits and trade offs in efficiency, fouling resistance, and cost.
We provide responsive, nationwide coverage for our services, including the metropolitan areas of Houston, Dallas, Chicago, Detroit, Milwaukee, Minneapolis, and The Northeast.