Rinnai continuous flow hot water system specified in food manufacturer plant

  • 28 Jan 2020

A Rinnai continuous flow hot water solution was recently installed at a large-scale seafood processing and manufacturing plant on the North East coast.

The food manufacture site had an old stored hot water system which was no longer able to cope with the demand for the high volume and high-temperature hot water needed for cleaning down production areas as the site increased its production lines, as it expanded its market ordering and product range.

In addition, there were long periods of time with no requirements for hot water, then sudden high demand as production areas need deep cleaning. Running out of hot water would, therefore, result in substandard cleaning, especially the removal of grease, and industrial cleaning products used to clean many of the surfaces.  

Another key factor was that the site was also looking to substantially increase energy, fuel cost efficiency and reliability by removing the stored hot water.

Rinnai’s ability to resist Legionella breeding which is a risk with a “lukewarm” hot water system, made it ideal for the plant. 

Plus, with Rinnai continuous flow units water temperature for distribution is accurate to ±1˚C. The fact that there is no stratification as there is no storage, ensures a continuous, permanent even temperature. There is no requirement to heat a volume of water just to ensure the elimination of Legionella bacteria as the minimum temperature that a continuous flow unit achieves is in excess of advisory levels.

The modular nature of the Rinnai Systems also removes a single point of failure from the hot water system, ensuring hot water will always be available and not run out. The site used 3 x HDC1200i Natural Gas Water Heaters and also featured the Rinnai Limescale Protection Package.

The Rinnai HDC 1200i continuous flow hot water unit has the capacity to easily deliver in excess of 1560 litres of hot water in excess of 50 degrees C temperature per hour, with an overall gross efficiency of more than 95%. These levels of performance, with unbeatable efficiency levels, mean the Rinnai 1200i is more than capable of meeting and exceeding the hot water demands of all applications.

This precision-engineered unit can also be combined as multiple units into one single, easy to handle module incorporating cascade frames and common flue. Both the HDC 1200 internal and external models turn in a market-leading energy performance of 107% net efficiency and offer superlative ranges of modulation as the systems internal analytical system can modulate the burner modulation range from 54kw to 2.4kw. The Rinnai HDC 1200i is engineered for minimal energy wastage and maximum energy performance.

It is worth remembering that Part L of the Building Regulations 2013 has set minimum thermal efficiency levels of 90% for natural gas and 92% for LPG, consequently outlawing non-condensing gas-fired water heaters for use in new build projects.

Rinnai is the only manufacturer that can supply a complete range of internal and external ultra-high efficiency condensing continuous flow water heaters, aligned not only to comply but surpass changes on the regulatory horizon.

Rinnai units and systems are now the number one choice for any size of site or large building or business with a heavy demand for constant hot water or where high peaks of demand occur at certain times. Any number of modules can be manifolded, so the water handling capacity is truly infinite and there is no risk of the ‘cascade’ of hot water ever running out.

The manifolded 1200i units can be delivered direct to site in one complete, easy to manage package and at a very competitive price. For the end user this guarantees considerable cost savings over other forms of hot water generation. The relatively compact footprint of all Rinnai units and systems means it can optimise plant room space and safeguard accessibility for maintenance and servicing.

There is huge potential for on-demand style water heaters such as the Rinnai HDC 1200i units to play their part in new build and in refurbishments projects alike, where in the latter there are still many old systems that need replacing. By replacing this older technology with new condensing appliances will help support the UK drive towards greener industry.

The Rinnai Infinity HDC 1200i water heater uses heat exchanger technology to allow the largest capacity flow rates, thereby guaranteeing all the hot water needed, when it is needed. As well as increasing capacity, the Rinnai Infinity water heater has lower greenhouse emissions because of the new reduced NOx burner technology and as there is no storage, this scores well with BREEAM.

The only time the site uses energy to heat water is when there is a demand, in other words, it is only burning gas when a tap is being run.

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