Zell Em Group Factory
The Zell-Em Group required a comprehensive, multi-zone mechanical installation for their massive 4,500m² manufacturing plant and head offices. The project demanded a high-capacity, renewable energy heating solution capable of maintaining strict climate control across vast industrial spaces, specialized production lines, and corporate offices, while simultaneously integrating a heavy-duty industrial LPG supply for machinery.
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.
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