The Challenge

• Massive Industrial Scale: Designing a balanced infrastructure to evenly heat a 4,500m² multi-use facility, including high-ceiling warehouses and insulated office blocks.
• Complex Energy Integration: Installing one of the nation’s largest Biomass heating plants  +  Safely running a high-capacity industrial LPG line for production machinery.
• Varying Temperature Requirements: Engineering heating profiles for administrative staff comfort, warehouse storage safety, and precise manufacturing room conditions.

The Solution

Renewable Biomass Plantroom & Fuel Storage

• Flagship Twin Biomass System: Installed a massive 350kW twin ETA biomass boiler system—ranking as the second largest of its kind in the United Kingdom.
• Bespoke Wood Chip Store: Engineered a custom bulk fuel storage facility integrated with an automated mechanical auger feed system, maximizing efficiency and minimizing manual fuel handling.
• Thermal Energy Storage: Connected a 2,500-litre buffer vessel to act as a thermal flywheel, storing bulk heat energy to ensure steady, uninterrupted distribution across the entire complex.

Strategic 6-Zone Space Heating

• Zoned Infrastructure: Engineered a comprehensive 6-zone distribution network to isolate and manage independent climates for the Offices, Toilets, Warehouses, Main Factory Floor, Store Rooms, and Production Rooms.
• Industrial Warehousing & Factory Heating: Deployed powerful fan-assisted Hiline space heaters alongside ceiling-mounted radiant panels to deliver high-output, rapid warmth throughout the vast industrial areas.
• Commercial Office Heating: Installed an energy-efficient, responsive radiator network across the corporate administrative sectors to provide precise, comfortable temperature control.

Production Machinery Integration

• LPG Gas Infrastructure: Installed a dedicated, high-pressure 90kW LPG gas-fired pipeline specifically calibrated to power Zell-Em’s heavy industrial commercial printing machinery, ensuring flawless operational uptime.

Commercial Amenities & Plumbing

• High-Volume Water Services: Fitted out centralized unvented hot water cylinders to manage the domestic hot water network safely and efficiently.
• Staff Facilities: Executed full, turn-key plumbing installations across multiple public and staff sectors, including high-capacity Toilets, Canteens, and Employee Shower Rooms.

The Results

By deploying one of the UK’s largest commercial biomass installations, the Zell-Em Group successfully eliminated their reliance on standard fossil fuel heating for their 4,500m² envelope.

And in the process benefited from Grant payments available whilst lowering their carbon footprint.

The hybrid layout pairs ultra-low-carbon renewable heating with heavy-duty LPG machinery infrastructure.