Smaller factories and warehouses occupied by SMEs account for 66% of stock in the United Kingdom. On average, smaller factories and warehouses in the sector are sized around 15,000 square feet or less. Although the demand for larger UK warehouses has increased following increased logistics demand from pandemic and Brexit; smaller warehouses have implemented improved storage and operational measures to meet the changing landscape. This includes scalable racking areas to manage increased inventory, flexible work station systems to meet capacity and additional access points as rolling shutter doors are used more frequently.

How to Heat a Small Factory

Using Intelligent Control Systems from Tansun

Small factory heating and energy use are therefore critical considerations within the UK's industrial landscape. A vast array of small factory heating systems are available in today's market, making it challenging to understand their unique advantages and disadvantages compared to traditional gas-fired radiant or warm air blowers for small factories. The primary consideration for smaller factories, warehouses and logistics or storage facilities has to be a solution which balances their operational requirements and affordability. Many small factories are also on the road to decarbonisation, so considering the available options for heating solutions is an essential step. Tansun has produced a guide which looks at applications of heating in small factories and what the energy consumption considerations are.

Small Factory Energy Consumption (Including Heating)

According to an independent energy switching service company for the leading price comparison websites, the average energy usage for different types of businesses can be categorised into the below:

Small Factory Gas Consumption

Small Factory Electricity Consumption

Source: Bionic August (2023), to be used as a guide only. Actual energy uses may vary by industry, building structure and how gas and electricity is currently used.

Heating a Small Factory

When it comes to heating small factories and reducing overall energy usage, selecting the right heating system is crucial. Heating methods can also conceal hidden costs that impact on a small factory’s operational efficiency and budget.

Heating a Small Factory using a Gas-fired Radiant Unit System

• Initial Installation Costs: Gas-fired heating systems typically require a substantial upfront investment for equipment and installation, including assembly, gas pipework and flueing. Damaged goods or missing items can delay installation which can be time consuming and costly.
• Inefficiencies: As gas-fired warm air systems focus on heating air into the building, heat distribution can be uneven especially when roller doors are opened frequently. Gas-fired systems have a much lower efficiency which is why in many cases, gas-fired unit heating manufacturers and providers can over design - inputting higher levels of energy to begin with to try and compensate.
• Maintenance: Regular maintenance is essential to keep a gas-fired unit system working effectively, adding to long-term costs. In the event of a breakdown, this can disrupt total operational efficiency as well as worker productivity.

Heating a Small Factory Using Electric Infrared & Radiant Heaters

• Initial Installation Costs: Electric radiant heating systems have much lower installation costs compared to a gas system, even for a large scale total infrared heating system.
• Inefficiencies: Robust manufacturing techniques and suitable control measures minimise inefficiency measures offering targeted, directional heat where needed. Infrared heating (shortwave) typically runs at 100% efficiency at source.
• Maintenance: Electric radiant heating systems do not require any ongoing maintenance to ensure optimal performance and if choosing a well-designed and engineered product they often come with a ‘fit and forget’ reputation.
• Integration with Solar Panels: Pairing infrared heating with solar panel solutions can further reduce operational costs and enhance sustainability. Solar panels can provide a renewable source of electricity to power the infrared heaters, lowering energy bills and reducing the factory's carbon footprint. This integration is especially beneficial for factories looking to be entirely self-sufficient, adopting greener energy consumption habits to improve overall energy efficiency. 

How can a Factory Reduce its Energy Consumption?

The Answer: Using Controllers

Source: Energy Saving Trust (2023). 27p is regarded as an average estimate fixed tariff from Ofgem’s July 2023 price cap. Actual tariffs may vary according to your energy provider and agreed rates. A 100KW heating system has been presented as an example of input required in a retrofit project within a smaller older factory building. Depending on age of building, building fabric and insulation, this figure may vary.

The above energy saving scenario is not possible with gas heating systems. Evidently, though gas tariffs may be cheaper overall in the current climate – as a heating solution they offer lower levels of efficiency particularly for smaller factories. For factories of a small size who are on the route to decarbonisation, a fully controlled infrared heating system can bring costs and energy inputs down overall resulting in a highly energy efficient heating solution.

How can a Factory Reduce its Energy Consumption?

The Answer: Better Zone Control

Now that we’ve pinpointed the challenges associated with energy consumption in factories and the role that controllability can play in electric infrared heating systems to reduce outputs and save on energy costs, let’s look at the impacts using zoning.

Source: Energy Saving Trust (2023). 27p is regarded as an average estimate fixed tariff from Ofgem’s July 2023 price cap. Actual tariffs may vary according to your energy provider and agreed rates. A 100KW heating system has been presented as an example of input required in a retrofit project within a smaller older factory building. Depending on age of building, building fabric and insulation, this figure may vary.

Again, the above energy saving scenario is not possible with gas heating systems given its focus on heating the whole volume of space, often resulting in excess energy consumption and wastage.

Heating Comparison for a 5,000 Square Foot Small Factory

Average Cost for Heating a Small Factory

Below is an example of a Tansun Zonal Control System in effect. Within the 5,000 square foot factory, we have categorised 9 zones. Using intelligent Tansun technology, energy consumption can be optimised for a small factory according to occupancy needs and requirements.

Gas heating systems of different types are the most common type of method for heating a small factory. But many of these installations are a decade or in many cases decades old inefficient systems that are no longer fit for the modern world.

Tansun have a solution that is fit for the new era with complete flexibility, zonal controlling and intelligent dimming features to further enhance energy savings. This can also help small factories to meet their net zero decarbonisation targets.

Ready to upgrade your small factory's heating for efficiency and control? Contact Tansun today to discuss a tailored solution. Enhance comfort, reduce energy consumption and save on costs. Reach out now for a warmer, efficient tomorrow.