A Technical Guide to Selecting the Right Solvent Recycling Equipment

Choosing the appropriate solvent recycling system is a critical decision that can significantly influence operational efficiency, regulatory compliance, cost savings, and environmental performance. With numerous variables to consider—such as solvent composition, throughput volume, automation requirements, and safety concerns—it is essential to take a structured, evidence-based approach when evaluating equipment options.

This guide provides an overview of the key technical considerations involved in selecting the most suitable solvent recycling system for your industrial application.

1. Volume Requirements and Throughput Capacity

An accurate assessment of your weekly or daily solvent waste volume is the foundational step in selecting the right system. Equipment must be appropriately scaled to match the waste output of your operation without causing process bottlenecks or excess downtime.

• Low to Mid-Volume Applications: Maratek’s Solvent Saver Batch (SSB) series is ideal for operations generating lower solvent waste volumes. These compact units are available in standard capacities of 8, 16, 32, 48, and 64 gallons per cycle.
• Mid-Complexity Waste Streams: The Solvent Saver Batch Premium (SSBP) series offers enhanced capabilities and automation. These units are available in 32 and 110-gallon models and are designed to handle more complex or viscous waste streams.
• High-Volume Industrial Applications: For continuous, high-throughput operations, the Solvent Saver Continuous (SSC) systems are engineered to handle flow rates ranging from 5 to over 100 gallons per hour. These systems also incorporate an internal scraper/mixer to manage high viscosity or high sludge applications.

For solvent streams with close-boiling components or requirements for ultra-high purity, a fractional distillation column can be integrated into SSC systems. This addition enables more precise separation and recovery of complex solvent mixtures.

2. Automation and Process Control

Automation plays a central role in optimizing solvent recovery processes, reducing labor requirements, and ensuring consistent product quality. The level of automation required depends on your operational needs and technical capacity.

• Basic Automation: The SSB series provides cost-effective recycling for simple waste streams with limited automation. These systems are manually operated and require operator supervision for filling and collection.
  
  
• Intermediate Automation: The SSBP series includes enhanced features such as:
  
  
  • Auto-fill capabilities
  • Integrated sensors and alarms
  • PLC touchscreen control interface
  • Ethernet-enabled remote monitoring and diagnostics
    
    
• Advanced Automation: The SSC series is engineered for fully automated, industrial-scale operations and includes:
  
  
  • Dual automatic filling and waste discharge
  • Auto-clean solvent output
  • Internal scrapers for sludge removal
  • Integrated vacuum systems
  • Remote control via Ethernet, Wi-Fi, or optional cellular access

These features minimize operator intervention, reduce human error, and ensure safe, efficient, and scalable operation.

3. Batch vs. Continuous Operation Modes

Understanding the operational differences between batch and continuous systems is crucial:

• Batch Recycling: Suitable for small to medium facilities, batch systems are filled manually and processed in discrete cycles. The operator must return after the cycle to remove the recovered solvent and waste byproduct.
  
  
• Continuous Recycling: These systems automate the solvent handling process, allowing ongoing operation with minimal human input. They are ideal for high-throughput facilities that require uninterrupted processing and higher efficiency.

Maratek’s SSC units provide continuous distillation with customizable automation to accommodate a wide range of industrial needs.

4. Solvent Boiling Point and the Role of Vacuum Technology

Boiling point data is a key design input in solvent recovery systems. For solvents with high boiling points or thermally sensitive compounds, incorporating a vacuum distillation module is highly advantageous.

Vacuum-assisted systems:

• Reduce the boiling point of solvents, enabling distillation at lower temperatures
  
  
• Minimize thermal degradation of sensitive compounds
• Lower overall energy consumption
• Improve solvent recovery yields
• Reduce fouling and wear on system components

These benefits are particularly important in pharmaceutical, aerospace, or coatings industries, where product purity and process integrity are critical.

5. Safety and Regulatory Compliance

Solvent recovery involves handling flammable, volatile, and potentially reactive substances. Equipment must meet or exceed all relevant safety standards, particularly when managing waste streams containing high-risk materials like nitrocellulose, which can self-ignite or release hazardous fumes.

Maratek offers specialized safety features across its product lines, including:

• Auto-cooling systems to prevent overheating
• Vacuum-sealed enclosures to minimize vapor release
  Steel conical distillation chambers for structural integrity
• Internal scrapers to prevent buildup of reactive residues
• Explosion-proof components (where applicable)
• Real-time remote monitoring and emergency shutoff protocols

All systems are built in compliance with international codes (e.g., CSA, UL, CE, ATEX, NFPA) and can be customized to meet specific jurisdictional requirements.

Engineering Support and Equipment Customization

Maratek works collaboratively with clients to assess their waste stream profiles, production needs, space constraints, and regulatory obligations. Our engineering and sales teams provide:

• Waste stream compatibility analysis
• Energy and cost modeling
• Equipment customization options
• Pilot testing and validation
• Installation and commissioning support
• Ongoing technical service

Whether you're considering a turnkey solution or require a tailored system with integration into your existing production line, Maratek provides the technical expertise and operational flexibility to deliver optimal results.

About Maratek

With over five decades of industry leadership, Maratek is a globally recognized manufacturer of advanced solvent recovery and recycling systems. Our award-winning equipment is trusted across a wide range of sectors, including aerospace, automotive, medical, printing, and industrial manufacturing.

Each unit is engineered for durability, process safety, and environmental performance, supporting clients in meeting evolving regulatory demands and sustainability goals.

Start Your Evaluation Today

Selecting the right solvent recycling system is a critical strategic decision with long-term financial, operational, and environmental implications. Maratek is here to assist you every step of the way.

Contact us to schedule a consultation, request a waste stream analysis, or explore how our Solvent Saver series can support your sustainability and cost-reduction goals.