Carbon Fiber Manufacturing Case Study

Project Summary

Reznor Photon 45kW Heating Upgrade for Carbon Fiber Manufacturing Facility in Leeds: Delivered in partnership with Heatworx Northwest Ltd

The client previously relied on three radiant tube heaters. While these provided intense heat directly beneath the tubes, they failed to warm the wider workspace as effectively.

Staff working under the tubes were uncomfortably hot, while those positioned to the side experienced little benefit.

The existing heating system created several operational issues:

•            Uneven heat distribution across the workspace

•            Overheating directly beneath radiant tubes

•            Cold zones in surrounding areas

•            High energy consumption (66kW installed load)

•            Reduced staff comfort and inconsistent working conditions

These issues affected productivity, comfort, and energy efficiency. The inconsistent temperatures made it difficult to maintain a stable working environment, and the high‑output radiant system consumed more energy than necessary.

Following a detailed free site survey, it was recommended that the client transitioned from radiant tubes to a warm air heating system. This approach would allow the entire space to be heated evenly rather than relying on directional radiant heat.

The project was delivered by Heatworx Northwest Ltd, an experienced HVAC contractor specialising in industrial heating installations. Their team along with Reznor supported the installation, commissioning, and on‑site coordination to ensure a smooth and efficient industrial heating upgrade.

Objective

The client opted to replace the outdated system with a Reznor Photon 45kW warm air unit supported by a destratification fan, ensuring even heat distribution throughout the entire area to improve factory and workshop heating.

The client aimed to:

•            Achieve consistent, comfortable heating across the entire factory area

•            Reduce energy consumption and running costs

•            Improve working conditions for staff

•            Replace outdated equipment with a modern, efficient heating solution

•            Ensure the system could be expanded to other areas in the future

Heatworx Northwest Ltd installed:

•            Reznor Photon 45kW warm air heater

•            Destratification fan to recirculate warm air trapped at high level

•            Smartcom Multizone control system for improved efficiency and temperature regulation

The destratification fan plays a key role in reducing heat stratification, ensuring warm air is pushed back down to working level and minimising energy waste.

Communication between the contractor and the client was smooth throughout, and commissioning was completed by our trusted service team without issue.

The new system delivered immediate and measurable improvements:

•            Installed heating capacity reduced from 66kW to 45kW

•            Lower energy consumption with improved comfort

•            Even heat distribution across the entire workspace

•            Noticeably improved working conditions for staff

•            Positive feedback from the goods‑inwards team, who reported the area felt “overall warmer”

The client now heats the space more effectively using 25% less installed kW.

Client Feedback

The client expressed strong satisfaction with both the performance of the new Reznor industrial warm air heating system and the installation quality delivered by Heatworx Northwest Ltd. Within a week, they enquired about installing an additional heater in another area of the building — a clear sign of confidence in the solution.

This project successfully modernised the heating system of a carbon fibre manufacturing facility in Leeds. By replacing outdated radiant tubes with a Reznor Photon warm air heater and destratification system, installed by Heatworx Northwest Ltd, the client achieved:

•            Reduced energy usage

•            Improved heat distribution

•            Enhanced staff comfort

•            A scalable heating solution for future expansion

Future Outlook

Following the success of this installation, the client is now exploring heating upgrades for additional areas of the building. The new Reznor system provides a reliable, efficient foundation for long‑term environmental control across their manufacturing site.