The factory decided to upgrade its hot water generation since the existing system of two, 1000-litre calorifiers couldn’t keep up with demand from the site’s cleaning operations, especially at weekends. "Although we are often producing at the weekend we don’t usually have every line running, so that’s when we wash absolutely everything," says Central Services Charge Hand Graham Walker. "The problem with calorifiers is that if you take out 500 litres you have to put 500 litres of cold water in and start heating that up again. It wasn’t very efficient and we couldn’t meet demand, causing delays in cleaning, and increasing our operating costs."
The EasiHeat system uses a steam-to-hot water plate heat exchanger to provide domestic hot water on demand. The compact system was supplied skid-mounted and ready to connect to the site’s utilities. This approach is typically much more energy efficient than systems relying on stored hot water because it eliminates a significant proportion of heat losses. "Cost savings are definitely there, although I’m not in a position to say exactly how much we’ve saved," says Mr. Walker.
Usually, the installation of EasiHeats enables an organisation to eliminate hot water storage entirely, but in the case of the Fox’s factory the site’s operating schedule means that the two calorifiers can still be used as buffers. "We might have people cleaning until five or six o’clock on a Saturday, but having the buffer vessels means we can turn off the boilers at three o’clock if we’ve finished producing, which further improves energy efficiency," says Mr. Walker.
The hot water system is set up so that the EasiHeat feeds the factory’s taps directly on demand and can also maintain the temperature in the buffer vessels when it would otherwise be idle.
"Everything’s worked fine since the new set-up was installed," he adds.
The skid-mounted design of EasiHeat Engineered System uses 1.2m3 of space to deliver up to 1,800 kW of heating power. Installation is quick because the complete package only needs to be hooked up to the site’s services and commissioned, saving the time and costs involved in building conventional heating systems on site.
Furthermore, the whole package is factory tested and guaranteed to work as specified, eliminating the risk of compatibility problems between components.
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