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Biomass Heating System helps to Cut Costs for Welsh Manufacturer


Thermal Earth (UK)
has helped reduce the fuel cost of a neighbouring business by
installing a biomass boiler heating system. Industrial GRP, a South
Wales manufacturer of glass reinforced plastic products, had three
Ponast wood pellet boilers installed in a cascade arrangement by Thermal
Earth to provide 186 kW of energy efficient heating for the warehouse
and offices.

The biomass boiler system will lower running costs and ensure that
Industrial GRP reduce its carbon footprint whilst saving on money on
heating bills and gaining an estimated £21,000 annually through the
non-domestic RHI scheme.

As one of the UK’s largest glass
reinforced plastic manufacturers, Industrial GRP has grown to employ
over 80 staff since it was founded in 1999 and serves customers globally
in the industrial and commercial sectors. Designing and building a
variety of GRP products including kiosks, cabinets and enclosures, the
market spans a wide range of areas from water and electric companies to
gas infrastructure contractors, renewable energy and large construction

Being an environmentally conscious organisation, Industrial GRP is
keen to minimise any impact on the environment its facilities may have.
In evaluating its heating system it was quickly identified that changing
to a biomass boiler system would significantly increase green
credentials. Thermal Earth installed the Ponast KP63 wood pellet
boilers, recommended for their manufacturing quality and ease of use.
The cascade arrangement ensures that while one boiler is undergoing
maintenance or repair the other boilers can still run and meet the
majority of the building’s demand.

The automatic KP63 Ponast boiler is a new product based on the
previous KP62 model but with additional features such as the modern
control unit with easy to use touch screen monitoring. The sophisticated
controls allow up to five heating circuits including domestic hot
water, accumulator tanks and solar system to be run from one device.
Furthermore, the new burner construction comprising a cast-iron
exchangeable burner surface and improved insulation allows for higher
combustion efficiency and therefore an increase in fuel savings.

A new radiator system along with fan coil units into the warehouse
were installed to enhance the efficiency of the new heating system.
Payback through the RHI payments is estimated at around five years, with
further savings being made on the reduced running costs. The initial
costs of £110,000 will be recovered in five years, with £21,000 pa RHI
payments coming in for a further 15 years.

The versatility of the Industrial GRP products has resulted in a
collaboration between Thermal Earth and the product manufacturers on
biomass installations where outbuildings are needed to be found to
accommodate the heating system. A brick structure would be time
consuming, costly and involve the application for necessary planning
permissions. Industrial GRP can build bespoke GRP kiosks to house
biomass boilers and fuel storage with fire rated partitions, emergency
door access and ventilation, achieving all safety standards and
providing a quick, cost effective solution.

Industry GRP site manager, Darren Tancock, commented, “Having worked
with Thermal Earth previously they were our first choice to install
biomass boilers in all of our factories. Their service was very
professional and the whole installation process was seamless. We are so
pleased with everything we are bringing forward the final phase of the
installation from September to March. Thermal Earth will definitely be
our first port of call for all our future
energy needs.”

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