Irish Pressings Co. Donegal

Project Overview

This project involved the supply, design, and installation of 2 MasterTherm AQ75ZHX units for the factory area to implement an innovative heat recovery system for a factory floor, and 2 MasterTherm BA60iS units for the new office facilities. The factory operates induction and pressing machines that generate significant waste heat, which was previously lost to the atmosphere. The goal was to capture and reuse this heat to provide efficient space heating while reducing energy costs and carbon emissions.

Scope of Work

  • Provide efficient space heating for the factory floor and office areas
  • Capture and reuse heat rejected by machinery to reduce energy waste
  • Allocate heat effectively across heating circuits based on demand
  • Maintain precise control of heating water temperature and ambient room temperature
  • Minimize CO₂ emissions and reduce operational costs compared to traditional heating solutions

System Description

  • 2 × MasterTherm AQ75ZHX Units
  • Installed to supply cooling to induction and pressing machines
  • Capture rejected heat via a heat exchanger connected to the machines’ brine circuit
  • Recovered heat is pumped through a buffer vessel before being sent to an Air Handling Unit (AHU) heating coil, efficiently heating the factory floor
  • 2 × MasterTherm BA60iS Units
  • Provide dedicated heating and cooling to the factory’s office spaces
  • Inverter-driven technology ensures precise temperature control and energy efficiency

Project Results & Benefits

  • Successful integration of a heat recovery system that captures previously wasted heat energy
  • Significant reduction in the factory’s carbon footprint by repurposing rejected heat
  • Optimized heating system leading to lower energy bills and improved operational efficiency
  • Smooth delivery, installation, and commissioning of all equipment with minimal disruption

Technical Highlights

  • Heat-recovery loop designed to lift low-grade process heat (e.g., 25–35 °C brine) to LTHW supply temperatures (e.g., 45–75 °C) for space heating.
  • Primary buffer tank sized ~10–15 L per kW to stabilise ΔT, protect compressors, and avoid short-cycling during intermittent process loads.
  • Three-way diverting valve logic prioritises heat recovery to the buffer/AHU and rejects excess heat to ambient only when storage is satisfied.
  • Integrated metering (electric + thermal) enables measurement & verification (M&V) of recovered heat for performance reporting.

Energy & Carbon (SEAI)

By harvesting waste heat and replacing fossil-fired space heating, the site reduces Scope 1 emissions and total CO₂ intensity. Heat-pump operation benefits from elevated source temperatures, improving COP and further cutting electricity use per kWh of heat delivered.

  • Approach aligns with SEAI guidance on waste-heat recovery and industrial decarbonisation.
  • Suitable for SEAI-style M&V frameworks and ongoing reporting.
Irish Pressings Automative