Services | Heatcatcher New Site

From First Assessment to Verified Savings

Heat decarbonisation is a process we support through every stage from idea to realisation.

Our process is split work across four stages: the Heat Recovery Study, the Front-End Engineering Design, Installation and Commissioning, and Optimisation and Monitoring. Each one builds on the last, and each one is designed to remove risk before you commit further budget.

The Heat Recovery Study

Before anything is designed or costed, we need to understand your site’s manufacturing process and utilities.

A Heat Recovery Study starts with a site visit. We map where heat is currently being lost in your process, whether that's kiln exhaust, dryer stacks, curing chamber losses, or boiler flue gas, and quantify how much of it is realistically recoverable.

Because we're technology-agnostic, we're not selling you a predetermined solution. We assess whether high temperature heat pumps, heat exchangers, or another approach fits your process best, then model the likely energy savings, carbon reduction and payback period.

You come out of this stage with a clear, costed picture of what's possible on your site, and whether it's worth proceeding, before committing to any design or capital spend.

What's included:

Site visit and process assessment
Identification and quantification of recoverable waste heat streams
Technology recommendation based on your specific process, not a fixed product line
Indicative payback period and carbon reduction figures
A clear go/no-go decision point, at low cost and low risk

The FEED Phase

FEED stands for Front End Engineering Design. This is where the study becomes an engineered plan.

We take the recommended approach from the Heat Recovery Study and turn it into a detailed technical design: equipment sizing, integration with your existing plant and controls, utility and space requirements, and a firm cost for delivery.

This stage exists to remove uncertainty before you commit to installation. You'll know exactly what's being built, how it fits around your process, what disruption to expect (and how we'll minimise it), and what it will cost, with no surprises further down the line.

What's included:

Detailed engineering design and equipment specification
Integration planning with existing plant, chambers and controls
A production continuity plan, so operations teams know what to expect
Firm project costing and delivery timeline
Risk assessment and mitigation planning

Installation and Commissioning

This is where the project gets built, and where our role as Designer and Contractor matters most.

We manage delivery end to end: procurement, site works, equipment installation, and commissioning. Installations are sequenced around your production schedule, not the other way round, because we know a decarbonisation project that stops your line is a decarbonisation project that costs you in lost production.

Once installed, systems go through full commissioning, performance testing and training for operators and maintenance teams before hand over.

What's included:

Designer and Contractor responsibility for the full installation
Procurement of equipment and management of labour
Installation sequenced to minimise disruption to production
Full commissioning and performance testing
Handover documentation and operational training for your team

Monitoring & Optimisation

Once your system is operational, we track performance against the savings modelled at the FEED stage, so the savings you were projected are the savings in practice. Where performance can be improved through control adjustments or operational changes, we recommend those improvement with supporting data.

For sites with thermal storage as part of their heat pump system, we also monitor opportunities to participate in the National Grid's Balancing Mechanism, which can turn the same asset into an additional revenue stream.

What's included:

Ongoing performance monitoring against projected savings
Regular reporting, so results are visible and verifiable
Ongoing recommendations for optimisation of the manufacturing process
Assessment of Balancing Mechanism revenue potential, where applicable

Talk to us about your site

Your kiln, dryer or curing chamber is losing heat right now. Find out what that's costing you.

A Heat Recovery Study gives you a clear, costed answer, not a sales pitch, within weeks. There's no long-term commitment to find out what's possible on your site.

Book Your Heat Recovery Study