Case Studies

If our clients aren't happy with their new Infra-red heating system neither are we so we always follow up with them after installation just to ensure that everything is functioning up to our specific standards. That is usually when we receive some very gratifying feedback from our clients and just as importantly, their employees. Below are just a handful of case studies we have put together based on this feedback.

Hyannis Honda Autobody

The Situation
A 11,700sq.ft. auto body repair shop with 16ft average ceiling height. Previous heating was natural gas unit heaters. Complaints included high fuel bills, uneven heat, poor zone control, cold floors, hot ceilings, clogged heaters from air borne contaminates, slow heat recovery, & dust blowing from noisy unit heaters.

The Solution
Installed a five zone Infra-red system. Burners supplied with outside inlet combustion air eliminated previous frequent nuisance maintenance issues.

The Result
Sharp drop in annual fuel consumption while increasing quality of heat. Employees appreciate the several benefits including; no dust blowing, quietness, ease of multiple zoning, warm dry floors and the ability of vehicles to heat up quickly when brought in from winter elements. A 3.5 year payback was achieved.

Prev. Fuel Cost (Nat. Gas) New Fuel Cost (Nat Gas) Annual Savings
$11,241 / year
$5,716 / year
$5,525 (49%)

Algonquin Tennis Club

The Situation
The oil-fired furnaces that the Club previously had were noisy, drafty and resulted in random uneven heat across the courts, a total area of 14,400sq.ft.. The large expense and maintenance costs were literally through the roof and were made worse by the fact that the heaters remained on throughout the day - even while nobody was using the courts - due to their incredibly slow heat-up time.

The Solution
Based on the structural layout with an outer eave height of 20ft and a center peak height of 45ft, installing a single row of infra-red heaters along the full length of the center peak was the ideal solution for even distribution of heat across the courts.

The Result
The club's members now regularly comment on the improved comfort level, the eveness of heat across the whole court plus the lack of distraction from the new much quieter system.

Prev. Fuel Cost (Oil - $2/Gal) New Fuel Cost (Nat Gas) Annual Savings
$10,800 / year
$3,348 / year
$7,452 (69%)

Hollis Line Machine

The Situation
Hollis Line Machine is a precision machine job shop demanding a specific, even temperature due to tight machining tolerances. The overall building size is 40,000sq.ft. and the existing heating system was four over-sized oil fired furnaces. Individual zoning with the previous oil furnaces was not possible, as up to 36,000sq.ft. is wide open floorspace. Complaints relating to the old heating system were numerous: cold floors; drafty, noisy and dusty system; very inefficient heating system that was constantly clogged & contaminated from poor indoor air quality; very poor heat recovery when the outside doors were opened.

The Solution
An eight zone infra-red system was installed mere inches above the several overhead gantry cranes. Combustion air from outside supplies each burner individually, eliminating airborne contaminants from within the building due to the precise machining process.

The Result
Immense fuel cost savings with greatly improved comfort & individual zone control. Employees rave about eveness of heat, warm dry comfortable floors, quietness of infra-red, rapid heat recovery, & very quick warm up time when heaters have been in off mode. Also, additional floor space was gained with the elimination of the previous large oil fired furnaces.

Prev. Fuel Cost (Oil - $2/Gal) New Fuel Cost (Nat Gas) Annual Savings
$61,280 / year
$19,588 / year
$41,692 (68%)

North American Crane

The Situation
North American Crane is manufacturer of industrial bridge & gantry cranes. The facility is 39,000sq.ft. with 22ft high ceilings. Former heating method was with one centrally located natural gas fired air rotation furnace. This air rotation furnace occupied a 14ft x 22ft footprint within the center of a busy production area. With only one zone for 39,000sq.ft., efficiency, comfort, & reliabilty of a single source heater was troublesome. Heat was very uneven, particularily near outside overhead doors & drafty welding stations. Maintenance costs of the air rotation furnace were expensive & repairs were ongoing.

The Solution
A six zone infra-red system was installed. Heaters were mounted above gantry cranes with protective heat shields on cranes.

The Result
The multiple zoning, warm floors & product, & eveness of distribution gained rave reviews from employees. A three year payback was achieved. Management appreciates the simplicity of the infra-red system, the reliabilty and the "leave it alone" maintenance that is required. An added benefit is the production floor flows far more efficiently with the removal of the former giant sized furnace.

Prev. Fuel Cost (Oil - $2/Gal) New Fuel Cost (Nat Gas) Annual Savings
$40,355 / year
$19,740 / year
$20,855 (52%)

American Ramp

The Situation
American Ramp is a manufacturer of handicapped ramps. Shop demands include warehousing, fabrication, & painting. The facility is 18,400sq.ft. with an average ceiling height of 20ft. Frequent door openings aggravated the constantly cold environment, as the previously natural gas fired unit heaters could not keep up with this busy facilities demands. Cold wet floors existed, fuel consumption was high, zoning was near impossible, unit heaters required frequent maintenance & product that took days for the paint to cure. It is also important to note that this building is under a negative air pressure due to open style paint booths & welding exhaust fans, which added to the cold uncomfortable existance.

The Solution
A four zone infra-red system. Outside sealed combustion was installed to combat the challenges of paint fumes, filthy air from welding, & negative air pressure.

The Result
Annual fuel consumption dropped sharply. Comfort increased beyond American Ramp's expectations; employees are thrilled & not distracted by previous cold drafty conditions. Heat recovery is within minutes. Curing times of paint on product improved dramatically. A three year payback was achieved & the shop has never been more comfortable. Also, product can be packaged & shipped must quicker due to greatly improved paint curing times.

Prev. Fuel Cost (Nat. Gas) New Fuel Cost (Nat Gas) Annual Savings
$15,640 / year
$7,360 / year
$8,280 (53%)

Pagell Corporation

The Situation
Pagell Corporation is a job shop for the paper industry. The open shop area is 14,300sq.ft. with an average ceiling height of 24ft. The previous natural gas fired boiler with steam warm air unit heaters was very costly to operate, maintenance costs were high & troublesome, only one zone existed, unit heaters were noisy, and the heating was uneven.

The Solution
A two zone infra-red system was designed & installed.

The Result
Healthy ongoing annual fuel savings were achieved resulting in a two year payback. Very even heat distribution. Quiet, dust free operation. Employees immediately commented on warm comfortable floors & rapid heat up time when heating has been in an off mode.

Prev. Fuel Cost (Nat. Gas) New Fuel Cost (Nat Gas) Annual Savings
$14,116 / year
$6,015 / year
$8,140 (58%)

Isaacson Steel

A steel supplier & fabrication facility near the Canadian border, faced with the challenges of long, harsh winters. Facility size is 23,000sq.ft. with a 17ft ceiling. Previous heating was two oil fired floor mounted furnaces. Complaints included high fuel cost, uneven heat distribution, poor zone control, & cold steel when brought in from outside that would take several hours to warm up.

The Solution
Installed a three zone infra-red heating system. System was mounted above overhead cranes & outside combustion inlet air eliminated maintenance problems from airborne contaminants.

The Result
Reduction in fuel consumption. Greatly improved employee comfort. Rapid heat recovery. Product that now heats up quickly when brought inside from outside. Superior zone control, aiding in fuel savings. Achieved a 3-1/3 year payback.

Prev. Fuel Cost (Oil - $2/Gal) New Fuel Cost (Nat Gas) Annual Savings
$16,819 / year
$9,759 / year
$7,060 (42%)

Ultima Nimco Machine Co.

A machine shop located in a circa 1900 large mill building. Large floor plan, but the desire to only spot heat a few work stations that are open to the large unheated space. Previous attempts with portable kerosene warm air construction style heaters proved ineffective, noisy, smelly, & inconvenient. Any thoughts of warm air permanent heating were not considered due to the challenges of the spot heating requirment.

The Solution
Installed two infra-red heaters in individual work areas.

The Result
For a modest annual fuel cost, permanant, quality infra-red spot heat has been accomplished. Management reports that they were spending a similiar amount on kerosene fuel cost for construction style heaters. Employee satisfaction has been greatly improved. Quiet, care free operation. Quick heat up time from off mode.

Ongoing Fuel cost for Ultimate Nimco Machine Co. is now only $1,760 per year

 

 

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PO Box 10419
Bedford, NH 03110
Northern Phone: (603) 471-1414
Southern Phone: (860) 990-0061
Fax: (603) 471-9198
info@progressiveenergyinc.com

 

 

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