Inzonex Modular Insulation across the boiler house, feed water, hot water, ironers and dryer burner cabinets. 95 % heat-loss reduction. Removable, serviceable, engineered to each element.
Site visit on 25 May 2026 identified 255 m² of bare hot surface across six areas of the laundry — boiler house, feed water lines, hot-water distribution, flatwork ironers and gas-fired tumbler dryer burner cabinets. All addressable with removable Inzonex modules without modifying pipework, pumps or burners.
2 × Byworth Y2SZ3500-24 3-pass wetback firetube boilers (July 2016). 3,500 kg/h F&A 100 °C each. Design 10/13 BARG, saturated steam up to +190 °C. Both boilers in service — alternating weekly: 26 weeks production + 26 weeks hot standby per boiler per year. Steam feeds ironers, hot-water service and process heating.
5 flatwork ironers (4 large + 1 small) — steam-heated chests, top cabinet surface 66 °C measured. 14 Kannegiesser tumbler dryers — direct gas-fired (independent of the steam boilers), with burner + heat-exchanger cabinets on top of each drum. Surface temperature per face: front 84 °C / sides 100 °C / top ~115 °C / back 120 °C, measured on FLIR.
Heat loss is computed per ISO 12241:2008 using the surface temperature actually measured by FLIR (or stated by the client). Convective coefficient at 0.5 m/s indoor draft, radiative coefficient for painted/oxidised steel (ε = 0.85), ambient 30 °C. Outer surface temperatures land between 37 °C and 45 °C — well below the UK HSE 60 °C touch limit.
Inzonex Modular Insulation, 50 mm mineral-wool core (λ = 0.045 W/m·K at 100 °C mean), outer surface temperature 37–45 °C, fully removable, snap-fit + lacing closures, silicone-coated outer.
Bare: 590 – 2,340 W/m² depending on T_s (66 – 150 °C). Covered with 50 mm: 30 – 101 W/m². Average reduction across all surfaces: 95.0 %.
Steam cost (client-supplied): £31.28 / tonne generated by gas ≈ £45.94 / MWh thermal. Plant operating profile (all sections): 22 h/day × 4 mo + 20 h/day × 6 mo + 17 h/day × 2 mo = 7,340 h/yr. Boilers rotate weekly — one always on hot standby. CO₂ factor: 0.18293 kg/kWh gas.
The project can be delivered in phases — start with any single zone or commit to the full scope. Pricing, lead time and on-site work plan agreed per phase.
DN50 isolation valves, vertical multistage pump bodies (Ø300 × 1050 mm), Y-strainers, DN40 ball valves, DN50 bends, DN150 flanges, riser flanges. Medium 102 °C, shared between both boilers.
Rotated weekly — one always on hot standby. Per boiler: ~3,670 h production (28.1 kW saved) + ~3,670 h hot standby at 70 °C (11.1 kW saved). 11 element types per boiler — front door, burner flange, economizer inlet line + gas chamber, handhole, supports, rear assemblies, top valves.
Pneumatic PRV DN50, ABB flowmeter body (head excluded — T-limit), two flanged ball valves Ø111 × L220. 90 °C process line.
4 large multi-roll + 1 smaller (~20 % less area). Top cabinet surface 66 °C measured. Roof made almost entirely of lift-off panels — each panel jacketed individually, lifts together with the panel for maintenance access.
Kannegiesser gas-fired tumbler dryers, top-mounted burner + heat-exchanger cabinets. Surface temperature per face: front 84 °C, back 120 °C, sides 100 °C, top ~115 °C. Roughness ×1.40 for bolts, sight-glass frames, dampers, brackets, flue stubs. Single largest saving — 51 % of total annual benefit.
All surface temperatures below were taken on site with FLIR. 69 thermograms recorded across the plant. Top hotspot: 167 °C. Median peak: 101 °C. 51 of 69 frames showed at least one surface above 80 °C.
Bolted steel casing carrying boiler exhaust to the finned economizer above. Single largest bare element on each boiler.
14 of these sit bare on top of the gas-fired tumblers. Surface temperature per face: front 84 °C, sides 100 °C, top ~115 °C, back 120 °C. Largest single saving — £43,943 / year.
Bolted bridge-bar inspection cover with raised flange ring. 0.73 m² module removes 1.4 kW continuous loss.
Front face 2.0 × 0.8 m with 10 cm flange perimeter, perimeter bolts, lifting eye and burner mounting flange. 3.83 m² — single largest face on each boiler.
Header pipework above the pumps is already insulated. Every isolation valve, strainer, ball valve and pump body sits exposed.
Full thermogram set (69 shots, calibrated, with min/max/avg temperature overlay) and raw FLIR RJPEGs available on request. Pre-quote site visit will add per-face survey of every dryer cabinet and ironer roof for fabrication-grade dimensions.
Full bottom-up build by section. Bare and covered heat flux per element. Annual £/yr at £31.28 / tonne of steam (≈ £45.94 / MWh thermal) × 7,340 h/yr plant operating profile (22 h/day × 4 mo + 20 h/day × 6 mo + 17 h/day × 2 mo). Boilers rotate weekly — one always on hot standby.
| Section / Element | m² | T_s °C | Q_bare kW | Q_cov kW | Saved kW | £/yr |
|---|---|---|---|---|---|---|
| A · FEED WATER — 4 lines · 102 °C · 7,340 h/yr | ||||||
| Gate valves DN50 L250 × 4 | 0.72 | 102 | 0.91 | 0.04 | 0.86 | 290 |
| Pump body Ø300 × 1050 × 4 | 4.00 | 102 | 5.04 | 0.24 | 4.80 | 1,618 |
| Y-strainers × 4 | 0.64 | 102 | 0.81 | 0.04 | 0.77 | 260 |
| Ball valves DN40 × 4 | 0.48 | 102 | 0.60 | 0.03 | 0.58 | 195 |
| 90° bends DN50 × 4 | 0.25 | 102 | 0.31 | 0.02 | 0.30 | 101 |
| Flanges DN150 × 4 | 0.19 | 102 | 0.24 | 0.01 | 0.23 | 76 |
| Riser flanges DN50 × 2 | 0.20 | 102 | 0.25 | 0.01 | 0.24 | 81 |
| Section A subtotal | 6.48 | — | 8.17 | 0.40 | 7.77 | 2,621 |
| B + C · BOTH BOILERS — Byworth Y2SZ3500 × 2 · rotated weekly (one always firing, one in hot standby) · 3,670 h prod + 3,670 h standby per boiler | ||||||
| Production state — element-by-element, per boiler (£/yr column shown for both boilers combined = per-boiler × 2) | ||||||
| Front smokebox door | 2.65 | 105 | 3.50 | 0.17 | 3.33 | 1,123 |
| Burner flange | 1.18 | 133 | 2.28 | 0.10 | 2.18 | 735 |
| Economizer inlet line (DN25 flange + DN40 pipes + 4 valves + pneumatic regulator) | 1.15 | 97 | 1.34 | 0.06 | 1.28 | 432 |
| Side handhole Ø600 mm | 0.73 | 140 | 1.53 | 0.07 | 1.47 | 495 |
| Boiler saddle supports × 2 | 4.40 | 87 | 4.26 | 0.21 | 4.05 | 1,366 |
| Economizer gas-inlet chamber | 5.00 | 125 | 8.77 | 0.40 | 8.37 | 2,821 |
| Rear access door + canopy | 1.58 | 120 | 2.60 | 0.12 | 2.48 | 836 |
| Rear smokebox door Ø750 mm | 1.03 | 95 | 1.16 | 0.06 | 1.11 | 374 |
| Sensor flanges DN65 × 4 (top) | 0.60 | 150 | 1.40 | 0.06 | 1.34 | 452 |
| Safety valve 100/65 | 0.41 | 150 | 0.96 | 0.04 | 0.92 | 310 |
| Main DN150 steam stop valve | 0.72 | 150 | 1.69 | 0.07 | 1.61 | 543 |
| Production sub (per boiler × 2 = both boilers, 3,670 h each) | 19.45 | — | 29.49 | 1.36 | 28.14 | 9,487 |
| Standby state — all elements uniform at 70 °C (top assembly cold-isolated) | ||||||
| Boiler envelope minus top assembly · per boiler × 2 boilers (3,670 h standby each) | 17.72 | 70 | 11.70 | 0.60 | 11.09 | 3,740 |
| Section B+C subtotal (both boilers, full year) | 37.17 | — | — | — | — | 13,227 |
| D · HOT WATER · 90 °C · 7,340 h/yr | ||||||
| Pneumatic PRV DN50 | 0.25 | 90 | 0.26 | 0.01 | 0.25 | 83 |
| Flowmeter DN40 (body only) | 0.12 | 90 | 0.12 | 0.01 | 0.12 | 40 |
| Ball valves Ø111 × L220 × 2 | 0.28 | 90 | 0.29 | 0.01 | 0.28 | 93 |
| Section D subtotal | 0.65 | — | 0.67 | 0.03 | 0.64 | 216 |
| E · FLATWORK IRONERS — 5 machines · 66 °C · 7,340 h/yr (full roof = lift-off panels jacketed individually) | ||||||
| Ironer #1 (large) | 29.00 | 66 | 17.11 | 0.87 | 16.24 | 5,476 |
| Ironer #2 (large) | 29.00 | 66 | 17.11 | 0.87 | 16.24 | 5,476 |
| Ironer #3 (large) | 29.00 | 66 | 17.11 | 0.87 | 16.24 | 5,476 |
| Ironer #4 (large) | 29.00 | 66 | 17.11 | 0.87 | 16.24 | 5,476 |
| Ironer #5 (small, −20 %) | 23.20 | 66 | 13.69 | 0.70 | 12.99 | 4,380 |
| Section E subtotal | 139.20 | — | 82.13 | 4.18 | 77.95 | 26,284 |
| F · DRYER BURNER+HX MODULES — 14 units (Kannegiesser, ×1.40 roughness) · 7,340 h/yr | ||||||
| Front faces (× 14, 84 °C) | 31.90 | 84 | 29.28 | 1.44 | 27.85 | 9,391 |
| Back faces (× 14, 120 °C) | 31.90 | 120 | 52.41 | 2.42 | 49.99 | 16,856 |
| Top faces (× 14, ~115 °C est.) | 22.10 | 115 | 34.01 | 1.59 | 32.42 | 10,932 |
| Side faces (× 14 net, 100 °C) | 17.20 | 100 | 21.07 | 1.01 | 20.06 | 6,764 |
| Section F subtotal | 103.10 | — | 136.78 | 6.46 | 130.32 | 43,943 |
| GRAND TOTAL · all sections (50 mm jacket) | 286.60 | — | — | — | — | £86,291 |
Q_bare and Q_cov are continuous heat fluxes (steady-state) — covered values quoted at 50 mm Inzonex Modular Insulation jacket. £/yr is the steam-cost equivalent at £31.28/tonne (≈ £45.94/MWh thermal) applied across each section's 7,340 h/yr operating profile. Total heat saved: 1,878 MWh thermal/yr ≈ 2,758 tonnes of steam.
Each phase pays for itself, and combinations compound. Final pricing below — manufactured in Ukraine, delivered to UK, installed on site. Lead time 4–6 weeks after full on-site measurements.
Manufactured by contractor in Ukraine to GB2508992.1. Lead time 4–6 weeks from completion of full on-site measurements. Delivered DDP — all duties, taxes and broker services included in price. Installation 1–2 days per zone; dryer cabinets installed during scheduled shutdown window. Final price subject to confirmed access, paint condition, asbestos check and finalised face-by-face FLIR survey on dryer cabinets and ironer roofs.
Four-layer construction. Outer silicone-coated fabric (flame-retardant, oil and chemical resistant, washable). Aluminium foil radiation barrier. Mineral-wool core, density and thickness tuned per element. Inner silicone liner against the hot face. Closed with AISI 316 stainless snap fasteners and meta-aramid thread — no exposed steel wire to wear out.
