Green Bay, United States
Manufacturing
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Discover the cost-effective & reliable benefits of refurbished RTOs from KKI. Improve capital costs, performance & sustainability with refurbished RTO systems.
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Kono Kogs, Inc.
Verified
Green Bay, United StatesManufacturing
- Founded
- 1996
- Team Size
- 10-100
- Annual Revenue
- < $100M
- Stage
- Established (7+ years)
Kono Kogs, Inc. Overview
About Kono Kogs, Inc.
Kono Kogs, Inc. provides sustainable air pollution control solutions that help manufacturers meet ESG and environmental compliance goals. Specializing in new and refurbished regenerative thermal oxidizers (RTOs), catalytic oxidizers, and thermal oxidizers, we design systems that reduce VOC emissions, lower carbon footprint, and improve energy efficiency. With over 25 years of experience, Kono Kogs delivers turnkey engineering, installation, and long-term service. Our mission is to support cleaner, smarter manufacturing by extending equipment life and promoting responsible resource use—helping industries achieve measurable progress in sustainability and operational performance.
Company size servedEnterprise (1000+ employees) · Mid-market (100–999)
Solution typeHardware/equipment · Professional services
Deployment modelOn-premise
Pricing modelQuote-based · Project-based
Company stageEstablished (7+ years)
Industry focusCross-industry · Manufacturing
Geographic coverageGlobal · North America
Company size servedEnterprise (1000+ employees) · Mid-market (100–999)
Number of customers50–500
ClienteleGlobal
Solution typeHardware/equipment · Professional services
Deployment modelOn-premise
Pricing modelQuote-based · Project-based
Certifications Listed4
Founded1996
Products
Regenerative Thermal Oxidizers (RTOs)
High-efficiency RTO systems designed to destroy VOCs while minimizing energy use and operating costs.
VOC Rotary Concentrators
High-efficiency rotary concentrator systems designed to capture and concentrate VOCs for cost-effective emission control and reduced energy use.
Case Studies
Case StudyRefurbished RTO for Polycarbonate Manufacturer
Problem : A plastics company that offers various polycarbonate and acrylic sheets and rolls, started moving into the market of performance hard coated polycarbonate. The addition of this coating process caused the company to exceed the EPA threshold for VOC emissions , therefore requiring a pollution control device to remove those VOCs. Kono Kogs was approached by the company to provide a brand-new RTO option to accommodate the new process airflow. Solution : Kono Kogs provided a custom, completely refurbished regenerative thermal oxidizer that includes a two-chamber design, with structured ceramic media , a pneumatic poppet (switching) valve system and an optional VOC (Puff) chamber for a VOC destruction rate efficiency of ≥99%. It is designed to provide one of the lowest utility costs (fuel & electricity) of leading oxidizer systems. The RTO was completely designed and built in our warehouse & shop in Green Bay, Wisconsin . Our custom RTO systems have the best of the best, industry-proven technology , all designed to meet our primary aim of extreme reliability and long life. The RTO meets that aim with an intuitive and innovative (yet simple) design. Our custom RTO design was a cumulative effort of our exceptional engineers and designers holding decades of experience designing oxidizer systems for nearly every industrial application. Equipment & Services Provided Custom built RTO with structured ceramic media and poppet valves VOC (Puff) Chamber Ship & mechanically assemble RTO Fabricate all process ductwork & T-dampers Equipment and crew to install RTO & ductwork Equipment commissioning Parts & VOC destruction guarantee What Makes Kono Kogs Different? Vertical Integration : We are vertically integrated, meaning we are able to design, fabricate, assemble, ship, install, and commission your oxidizer system with our people, and install it anywhere in the USA. No third parties. Just our talented fabrication team forming and assembling the innovatively simple RTO design, controlling quality, and timelines. Our in-house fabrication capability also benefits our customer's bottom line as there are no "middle-man" mark-ups for fabrication work. And throughout the project it is our team communicating seamlessly with our partner's team to accomplish a successful project, on time and on budget. Our on-site crews are our crews, led by our crew leaders, at the direction of our project engineer, working in partnership with your team. All with the high-level safety training and insurance coverage you should expect from your suppliers.
Case StudyDual VOC Rotary Concentrators for Automotive Manufacturing
Problem : When a major automotive manufacturer expanded capacity across several paint lines, the resulting increase in throughput caused their total VOC emissions to exceed applicable state and federal regulatory thresholds. The paint-shop exhaust stream contains solvents such as xylene, toluene, MEK, acetates, alcohols, and other hydrocarbon compounds. The customer required a high-efficiency, low-fuel-use solution capable of treating large paint-line airflows while maintaining high destruction efficiency. They also needed a system that could integrate with existing process equipment, operate continuously with minimal downtime, and support future production increases. Kono Kogs was tasked with engineering and providing a dual VOC rotary concentrator system integrated with a small Regenerative Thermal Oxidizer (RTO) , enabling substantial fuel savings relative to processing the entire exhaust volume through a full-size RTO. This design offers a durable, energy-efficient path to regulatory compliance. Solution : Kono Kogs delivered a dual VOC rotary concentrator (RC) solution specifically developed for high-volume automotive paint applications . The two parallel concentrator wheels adsorb VOCs from substantial process airflows and release them into a reduced, concentrated airstream for treatment in the thermal oxidizer. This method offers notable reductions in fuel demand, operating expenses, and overall system footprint. Equipment & Services Provided Dual zeolite VOC Rotary Concentrator wheels Regenerative thermal oxidizer for concentrated stream treatment Custom PLC/HMI controls and integration with paint-line equipment Fabrication of process ductwork, transition pieces, and valves Shipping, mechanical assembly & rigging of concentrator system and oxidizer Full installation of concentrators, oxidizer, and ductwork by Kono Kogs crews System commissioning, operator training & performance testing Parts support and VOC destruction guarantee What Makes Kono Kogs Different? Kono Kogs is fully vertically integrated—we design, fabricate, assemble, ship, install, and commission every oxidizer and concentrator system with our own team. No third-party fabricators. No subcontracted installation crews. This ensures: Consistent quality and tight control over production Faster timelines with fewer handoffs No middle-man markups on fabrication or installation Seamless communication with your project team Safer, more predictable on-site work led by our own foremen and project engineers Projects delivered on time and on budget Our team manages the entire process—from engineering and fabrication to installation and startup—providing unmatched accountability and reliability for large-scale automotive paint operations.
Case StudyCeramic Media Upgrade for Automotive Paint Line
Problem : Emissions from a Tier 1 automotive paint line were plugging the ceramic media beds in a 25,000 scfm regenerative thermal oxidizer (RTO). Frequent and costly ceramic media cleanings and replacements were harming production schedules and profitability. Paint emissions containing siloxanes were the source of the plugging. When the siloxanes are exposed to the high temperatures in an RTO ceramic media bed they form SiO₂ which adheres to the ceramic media surface. Over time, the particulate will fill what is referred to as the ‘void volume’ of the media and begin to plug the bed leading to increased pressure drop throughout the unit. To maintain the desired airflow draw from the spray booths the RTO fan speed increases to overcome the additional system airflow resistance due to plugging. The results are increased operating costs (fan horsepower) and decreased thermal efficiency (higher burner firing). Also, additional wear and tear on the RTO due to pressure spikes during valve switches. Solution : Kono Kogs was hired to analyze the plugging and develop a solution to extend ceramic media life. With proper ceramic media bed design, the bed life can be extended significantly and sometimes plugging can be alleviated completely. However with siloxanes, the plugging cannot be eliminated. In these cases understanding at what temperatures the creation of solid SiO₂ occurs determines the best solution. The bed design that offers the combined longest life and highest fuel efficiency was proposed. Kono Kogs worked with local contractors hired by our customer to facilitate COVID travel/work rules in 2021. Additional plugging was found in the cold face upon removal of the ceramic media, which was unexpected. Cleaning and cold face repairs were made to allow the desired 1 day media replacement to hold schedule. Kono Kogs left an extremely clean job site, and also re-started and confirmed proper RTO operation prior to leaving. Equipment & Services Provided Assessed media plugging characteristics Designed media bed optimizing life and thermal efficiency Provided ceramic media and oversight for replacement Ensured clean work site before leaving
Case StudyCustom Built RTO to Treat Food Packaging Emissions
Problem : A leading supplier food packaging was expanding, including the addition of a new flexographic printing press. Emission control for the press exhaust was required, along with additional capacity for existing presses which were being treated by an older catalytic oxidizer. A regenerative thermal oxidizer (RTO) was the preferred oxidizer technology. The new RTO would replace the existing system and providing increased VOC destruction efficiency and significant utility savings. In addition to the RTO, process ductwork and dampers were needed, as well as mechanical installation on the customer's concrete pad. Additional project requirements were for very high VOC destruction efficiency, as well as the ability to handle high VOC concentrations emitted by today's highly recirculating printing presses. Solution : Kono Kogs typically has over 25 existing RTO systems in our inventory, of only the best-built OEM/models, in multiple capacities and types. But for this particular application we did not have a match desired by the customer: 25,000 scfm capacity with poppet style switching valves, hot gas bypass system, and a puff capture feature. A custom RTO was proposed which included a VOC entrapment (puff capture) option, and a hot gas bypass feature. Our custom RTO systems have the best of the best, industry-proven technology, all designed to meet our primary aim of extreme reliability and long life. The RTO meets that aim with an intuitive and innovative (yet simple) design. Our custom RTO design was a cumulative effort of our exceptional engineers and designers holding decades of experience designing oxidizer systems for nearly every industrial application. This was our 4th project together with this food packaging manufacturer, and our second system installation for them. The first unit was a successful, refurbished 16,000 scfm RTO in 2023. We value partnerships like this one; we seek to optimize our customer's capital spending with common sense, ultra-reliable oxidizer solutions and provide exceptional after-sale support, from remote monitoring, to preventive maintenance schedules and reminders, and well stocked spare parts inventories. All in an effort to be a reliable partner in the successful emission control of their printing emissions. Equipment & Services Provided Custom Built RTO w/structured media & poppet valves Ship & mechanically assemble RTO Fabricate all process ductwork & T-dampers Equipment and crew to install RTO and ductwork Equipment commissioning Parts & VOC destruction warranty Results : The partnership between Kono Kogs and our customer resulted in an exceptionally well-performing new (& refurbished/hybrid) RTO. The project completed on time and on budget, with extremely low process down-time needed to make the switch over from the catalytic oxidizer to the new RTO system. Our customer/partner has recently purchased a new, larger, custom RTO system from Kono Kogs. The purchased hinged on one important condition. The main requirement was that the same Kono Kogs personnel be assigned to the project who worked on the 25,000 RTO project. High praise that we appreciate hearing. We also know that it brings high expectations, which we certainly intend to live up to. Of course, we assigned the same team (though we believe all of our teams are exceptional). New & Refurbished Come Together : While the main RTO body consisting of the ceramic media chambers, combustion chamber and poppet valves was designed and built from the ground up in our shop for this project, the peripheral pieces were sourced from our large inventory of existing components, resulting in exceptional cost savings for our customer. The peripheral components consisted of an existing fan, and existing VOC entrapment (puff capture) system, burner, and isolation dampers.
Case StudyProactive Prevention: How KONOConnect’s Alerts Avoided a Costly Shutdown
Problem : A manufacturing plant faced a potential shutdown due to an over-temperature alarm on their RTO control house. If left unaddressed, this issue could have led to the overheating of the electrical control system, specifically the AC drive, causing significant production downtime. Solution : With the KONOConnect system in place, the plant had established critical downtime alerts to notify critical personnel when specific RTO alarms and fault codes appeared. When the over-temperature alarm was triggered, an automatic alert was immediately emailed to the end customer. This prompt notification allowed the customer to quickly inform their maintenance department about the issue. The maintenance team was able to investigate and resolve the over-temperature problem before it escalated. By addressing the issue promptly, they prevented the electrical control system from overheating and avoided a potential shutdown. Detailed Steps Taken Alert Configuration : The KONOConnect system was configured to send automatic alerts for specific alarms and fault codes, including over-temperature conditions. Automatic Notification : Upon detecting the over-temperature alarm, KONOConnect sent an immediate email alert to the customer. Maintenance Response : The customer’s maintenance department was promptly informed and dispatched to investigate the issue. Issue Resolution : The maintenance team identified and resolved the over-temperature condition, ensuring that the RTO control house remained within safe operating temperatures. Prevention of Downtime : By addressing the issue swiftly, the plant avoided a shutdown of the electrical control system, maintaining continuous operation. Outcome : The KONOConnect system’s automated alerts enabled the customer to take proactive measures, preventing a potential shutdown and ensuring uninterrupted production. The ability to receive real-time notifications, and respond quickly to issues, demonstrated the value of KONOConnect in maintaining operational efficiency. Benefits Highlighted Proactive Maintenance : Automated alerts allowed for immediate action, preventing minor issues from becoming major problems. Minimized Downtime : Quick response to the over-temperature alarm prevented a shutdown, ensuring continuous production. Cost Savings : Avoiding a shutdown saved the customer from potential production losses and repair costs. Enhanced Reliability : The incident showcased the reliability and effectiveness of the KONOConnect system in monitoring and maintaining critical equipment. This case study highlights the proactive capabilities of the KONOConnect system in preventing potential shutdowns and maintaining operational efficiency. By providing real-time alerts and enabling swift responses, KONOConnect ensures that customers can address issues before they impact production. Reach out for a KONOConnect quote today and ensure expert monitoring of your oxidizer system, safeguarding your essential revenue-generating operations! Combine KONOConnect with our all-inclusive KONOCare Preventive Maintenance packages and be the hero when incidents arise like the one described above.
Certifications
Northeast Wisconsin Manufacturers Alliance
International Metal Decorators & Packaging Association (IMDPA).webp%3Falt%3Dmedia%26token%3D98d6abd0-af45-4049-a518-7976f3e20df3&w=256&q=75)
The National Safety Council
ISNetworld: Safety Network (ISN)Reviews
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Media & Press
konokogs.com
konokogs.comFrequently Asked Thermal Oxidizer Questions | Kono Kogs
Do you have thermal oxidizer questions? Kono Kogs has answers! Read our thermal oxidizer FAQ about oxidizer applications, cost, selection, and service.
Open linkkonokogs.comRefurbishing Before & After
At Kono Kogs, we specialize in transforming a wide range of oxidizers and equipment. Our before and after photos highlight the care and expertise we apply to each project.
Open linkkonokogs.comIndustries & Applications Served | Kono Kogs
Regardless of your industry or application, Kono Kogs provides used thermal oxidizers, planning, installation, service, and supplies to meet your air pollution control needs.
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konokogs.comThermal Oxidizer Videos - Educational, Installation & Refurbishing
Thermal oxidizer and regenerative thermal oxidizer (RTO) training videos featuring operational basics, construction, and design details
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www.konokogs.com
Head office in Green BayGreen Bay, United States
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