Manufacturing
Heat Recovery
Boiler economisers, process exhaust recovery, and compressed air heat capture.
Universal heat recovery solutions for every manufacturing sector — capturing waste heat from boilers, ovens, kilns, compressors, and process equipment. SS 304L construction with 250–3,500 kW capacity and 12–18 month typical payback on boiler economisers.
Three Models,
One Solution
Compact boiler economiser that fits into existing flue gas ducting — recovers 445-800 kW from boiler exhaust to preheat feedwater or process water. Typical payback under 18 months.
Heavy-duty plate heat exchanger for factory-wide heat recovery — transfers waste heat between process streams, cooling systems, and heating circuits at up to 3,500 kW capacity.
Air-to-air heat recovery from furnace exhaust, paint booth extraction, curing ovens, and industrial ventilation systems. Preheats incoming air to reduce heating energy consumption.
Manufacturing
Applications
Select an application to explore heat recovery opportunities for your factory.
Every manufacturing facility with a steam or hot water boiler is losing 15–20% of fuel energy through the stack. Our ThermStack TSE economisers recover heat from boiler flue gases (180–300°C) to preheat boiler feedwater, improving overall boiler efficiency by 4–8%. This is consistently the fastest-payback energy saving measure in manufacturing — typical payback is 12–18 months with no change to production processes. SS 304L construction handles condensing and non-condensing flue gas conditions.
Quick Payback
12–18 months on boiler economisers
Zero Disruption
No changes to production equipment
Full Range
250–3,500 kW across 12 models
Site Surveys
Free energy assessment available
Built for
Manufacturing
Key advantages for manufacturing heat recovery.
Stack Heat Recovery
Captures 445-800 kW from boiler flue gases at 180-300°C — the single fastest-payback measure in any factory.
Multi-Fuel Compatible
Handles flue gas from natural gas, LPG, oil, and dual-fuel boilers without material or design changes.
Feedwater Preheating
Raises boiler feedwater temperature by 20-40°C, reducing firing rate and improving overall boiler efficiency by 4-8%.
Condensing Capable
SS 304L resists the acidic condensate formed when flue gas drops below dew point — enabling deeper heat recovery.
Inline Installation
Mounts directly in existing flue ducting with standard flanges — no structural modifications to the boiler house.
Under 18-Month ROI
Consistently delivers 12-18 month payback across factory types — the lowest-risk energy investment available.
Universal Retrofit
Heat Recovery
Modular design fits any manufacturing exhaust — boiler stacks, process heaters, curing ovens, and drying systems.
Your Factory Is
Wasting Energy.
Every manufacturing facility has exhaust points venting recoverable thermal energy — boiler stacks, process heater flues, curing ovens, and drying systems. Our shell and tube heat exchangers capture this waste heat for preheating process water, combustion air, or space heating. Start with your highest-value exhaust point and scale across your facility.
Recover waste heat to preheat boiler feedwater or process streams — cutting fuel costs by up to 30%.
Modular design enables phased investment — start with one exhaust point and expand as you see returns.
Measurable CO₂ reductions from heat recovery — supporting ESG reporting and net zero targets.
Measurable CO₂ reductions from heat recovery — supporting ESG reporting and net zero targets.
Manufacturing
FAQs
Common questions about heat recovery for manufacturing operations.
Start with the quickest-payback opportunity: boiler flue gas economisers. If you have a steam or hot water boiler, a ThermStack TSE economiser typically achieves 12–18 month payback through fuel savings. Next, look at process exhaust recovery (ovens, kilns, furnaces) and compressor heat recovery. We can conduct a site energy survey to identify and prioritise all heat recovery opportunities.
Savings depend on your energy consumption and fuel prices. As a guide: boiler economisers save 4–8% of boiler fuel costs, process exhaust recovery saves 15–25% of oven/kiln fuel costs, and compressor heat recovery can displace equivalent space heating costs. For a factory spending £300,000/year on gas, total savings of £30,000–£60,000 per year are typical. We provide full ROI analysis with every proposal.
Minimal shutdown is required. Most installations need only a 1–2 day tie-in period during a planned maintenance window. Pre-fabricated connections and fully assembled heat exchanger units minimise on-site installation time. We plan installations around your production schedules to minimise disruption.
Absolutely. Compressors convert ~90% of input electricity to heat. If your factory spends £50,000/year on compressed air electricity, approximately £45,000 worth of heat is being wasted. Recovering even 50–70% of this for space or process heating displaces gas purchases. Payback is typically 18–24 months depending on heating season and recovery utilisation.
Yes. We regularly design and supply multiple heat recovery systems for single manufacturing sites — boiler economisers, oven exhaust recovery, and compressor heat recovery in a single project. We prioritise by payback period and can phase installations to spread capital expenditure. A single site energy survey covers all opportunities.
Maintenance is minimal. Boiler economisers (TSE range) typically need annual inspection and external cleaning. Process exhaust exchangers (EAA range) may need filter replacement and cleaning every 6–12 months depending on exhaust cleanliness. Shell and tube units (EST range) have removable end covers for tube bundle inspection. We provide maintenance schedules and can arrange service contracts.
Ready to
Recover?
Tell us about your factory and we'll identify the best heat recovery opportunities — starting with the quickest payback.
- Boiler flue gas economisers
- Oven & kiln exhaust recovery
- Compressed air heat capture
- Site energy surveys