Having moved from a facility that was too small and would have been uneconomical to upgrade, the overriding requirements for Elis’ new, state-of-the-art Southampton-based facility were to increase and future-proof throughput by increasing capacity as and when required. Protecting their investment was also paramount, so manufacturer-backed aftercare solutions were also key to the long-term plan.

The existing facility used a combination of indirect steam from a horizontal steam boiler and steam-heated ironers and dryers during the laundry process. But with the new multi-service flat linen plant – which services the Southern region hospitality and healthcare industry – came a new approach for Elis and, because the company processes laundry for the healthcare sector amongst others, they instead opted for a heat transfer system that would pre-heat water for the washing machines to a minimum of 72 degrees centigrade by directly injecting steam into the water supply.

A number of steam raising methods and manufacturers were considered in the original tender, but, with a requirement for an energy-efficient boiler with a small footprint, Elis subsequently placed an order for a skid-mounted, 2 x VSRT-60 gas-fired steam boiler solution from heat transfer specialist Fulton, which was packaged with ancillary items including automatic blowdown, water treatment and a TDS energy recovery system.

Commenting for Elis, senior engineer Slawomir Barczewski says: “The old facility was capable of processing 60,000 to 70,000 items a day but, with Fulton’s skid-mounted VSRT vertical steam boiler solution and the new line in place, we are currently processing approximately 90,000 items with the ability to double throughput as required.”

The skid-mounted solution features two 600kW (960kg/h) VSRT-60 steam boilers, which boast ultra-low NOx emissions of less than 20ppm, achieve up to 10:1 turndown capabilities and industry-leading performance of 86% gross thermal efficiency and 99.75% steam quality at 8 bar. It features a multi-award-design design that is durable, long-lasting, enhances heat transfer rates and improves steam quality. Additionally, for applications where contaminated air can reduce boiler uptime – such as laundry and dry cleaning facilities – the VSRT’s cyclonic air filter effectively separates debris and damaging particles from the combustion air and, because it won’t clog over time, eliminates the need for replacement filters.

To protect its investment and ensure the steam boiler installation continues to operate efficiently, Elis also opted for a number of solutions from Fulton’s aftercare portfolio, including a service contract, water treatment package and boiler operator training, a requirement of Elis’ insurance provider.

Commenting for Fulton, aftercare and business development manager Jeff Byrne says: “Considerable investment has gone into this new super-laundry and Elis is keen to ensure that their return-on-investment is improved as much as possible, hence supporting the installation with manufacturer-backed service contracts and training.”

The service contract for Elis consists of two service visits per boiler per year, with one visit coinciding with the annual insurance inspection. As well as providing discounts on any spares and the regular chemicals orders, the contract also ensures 24h phone-based technical assistance from a dedicated boiler/service engineer and a 48h call-out response where required. The water treatment package consists of monthly feedwater quality inspections and an annual system inspection and report.

Fulton’s one-day boiler operator training courses – accredited by the globally-recognised City & Guilds of London – has satisfied the boiler operational training requirements of hundreds of clients and bridges the gap between straightforward ‘toolbox’ training and the more expensive courses that can cost thousands per employee. Carried out on-site and supporting both BG01 (SAFed) and INDG-436 (HSE) guidelines, the course looks at the practical operation of controls and test equipment using a customer's own boiler, introduces the principles of steam and boiler operation in the form of a presentation and includes both theory and practical assessments.

For further information on Fulton’s skid-mounted solutions, the multi-award-winning VSRT or its aftercare portfolio, call +44 (0)117 972 3322 or visit www.fulton.co.uk. 

Fulton is delighted to announce the appointment of Stephen Finch as applications engineer. Stephen joined the leading steam boiler and heat transfer specialist just as the UK government announced its lockdown measures to combat Covid-19, but that hasn’t prevented Stephen, who has a degree in mechanical engineering and background in design engineering, from absorbing himself in his new role.

Commenting for Fulton, managing director Carl Knight says: “As we continue to innovate and look at new heat transfer solutions, like the multi-award-winning VSRT steam boiler, Stephen will play an essential role in product development. He will also be assisting the quality department in ensuring compliance for the company’s latest range of heat transfer equipment, including our fuel-fired and electric steam boilers; and providing engineering support for customers requiring bespoke skid-mounted boiler solutions featuring ancillaries including water treatment, chemical dosing and blowdown.”

Stephen’s career started as a project engineer at Eriks, but he joins Fulton from Renishaw where, as design supervisor, he was responsible for a team of engineers designing air preparation systems and automation projects for the metrology industry.

Outside of his work life, Stephen’s interest in automation means he likes to build his own machines and is also a keen woodworker. However, he is currently using his design engineering background and skills to assist a local community of engineers that are producing 3D printed face shields for essential workers at local hospitals and care homes in Bristol.

Heat transfer specialist Fulton will be using Foodex to showcase its range of fuel-fired and electric steam boiler solutions, launching its all-new boiler sequencing control system and promoting the many solutions on offer from its aftercare division. 

Launched at Foodex in 2018, Fulton will continue to promote the many radical features and benefits of the multi-award-winning VSRT vertical steam boiler – including the VSRT-250 due for launch this year – with the stand featuring a cut-away demonstration model of the VSRT-30 and a typical example of a skid mounted solution for food and beverage processing facilities that features a VSRT-15. 

Fulton will also be using its stand to launch the company’s all-new boiler sequencing control system which, with many food processing facilities operating multiple steam boilers, can optimise installations to ensure energy efficient operation and improve boiler longevity. Using sequencing to provide redundancy and reliability, Fulton predicts that significant savings can be made by automating start-up and shut-down procedures, controlling and optimising main steam header pressure or temperature, ensuring steam supply is controlled precisely for the required process and by eliminating idle time at low-fire.

Beyond its product portfolio, the company will also be showcasing the many solutions on offer from its aftercare division, which can support Fulton’s own installations and those from other boiler manufacturers. 

Commenting for Fulton, aftercare and business development manager Jeff Byrne says: “Since launch, the VSRT has proved extremely popular, especially within the food processing sector. So, while we continue to push the VSRT and promote its low total cost of ownership, we must also promote the many aftercare solutions Fulton offers.”

Fulton is renowned for its many gas-, oil- and electric-fired heat transfer solutions, but its service doesn’t just stop after a boiler is installed and commissioned. A food processing facility depends on its heat transfer equipment to maintain a regular supply of steam and, in many cases, during every hour of every day. So, when a boiler needs start-up, aftermarket parts, repair/maintenance or your operators require training, it’s essential that you use professionals that understand the often-complex capabilities of your processing equipment.

Using an analogy, Jeff explains that having invested in a new fleet of vehicles for its business, a company would be ill-advised to use unqualified mechanics or technicians to service them. “In the automotive industry, doing so would likely result in the manufacturer’s warranty being invalidated.” says Jeff. “But this is exactly what we’re seeing at facilities where boilers operators are often given little, poor or no training and are therefore unqualified and certainly unprepared when a fault occurs, or regular maintenance is required. A poorly maintained and serviced boiler could result in failure, significant process downtime and potential revenue losses.”

As well as offering boiler spares and repair service for all makes and types of heat transfer equipment, Fulton’s aftercare portfolio also includes accredited boiler operator training to INDG436 and BG01-R2, technical boiler house risk assessments, boiler and water treatment service contracts, water treatment training to BG04 and EN12953, steam trap surveys, site mass balance assessments and system design, etc.

For further information on the VSRT, boiler sequencing system or Fulton’s aftercare solutions, visit stand R269 at Foodex, call +44 (0)117 972 3322 or click www.fulton.co.uk. 

Having recently announced a series of appointments for its aftercare/service department, leading heat transfer specialist Fulton is continuing to strengthen its UK team with a number of senior roles changes.

Having joined Fulton in May 2017, Leigh Bryan has assumed the role of national consultant specialist at the company.

Commenting on the new role, managing director Carl Knight says: “In his previous role, Leigh was instrumental in successfully integrating the VSRT into Fulton’s current portfolio and introducing it to the UK market as the most radical change to vertical steam boiler design since Fulton pioneered the vertical tubeless boiler in 1949.

“In his new role, Leigh will remain an integral member of the management team and, thanks to the success of the ultra-low NOx VSRT steam boiler since its launch, will provide specification support, documentation and CPD training to specifiers and consultants across numerous markets.”

Ruth Price, who joined Fulton in 2012 as area sales manager for the North of England and North Wales, has also been promoted and, in her new role as senior sales engineer, will work closely with new and existing customers across the UK to advise on optimum boiler and steam systems specifications for their project.

For further information on the VSRT steam boiler or training available from Fulton, call +44 (0)117 972 3322, email sales@fulton.co.uk or visit www.fulton.co.uk. 

Fillongley Spring Water boasts one of the UK’s most efficient bottling facilities and offers a high-speed and cost-effective way for bottled water cooler distributors to access the high-quality product demanded by their customers. But with the demand for bottled cooler water increasing, Fillongley needed a new bottling line. However, with the two existing Fulton boilers not having the capacity to reach the target temperature for the new plant’s washing line, Fillongley started looking at alternative steam raising solutions. 

Commenting for Fillongley Spring Water, technical and quality manager Martin Whitehead says: “We looked at several alternatives – including vertical and horizontal firetube boilers – but, with advice from our main contractors and installer, a decision to specify one of Fulton’s recently-launched VSRT-30 steam boilers was taken and, overall, the results have exceeded expectations!”

Instead of running two boilers for the washing line, a single VSRT boiler is now being used to achieve an increased target temperature of 60°C for the detergent. The combination of the new line and Fulton’s energy-efficient VSRT also means the company has been able to increase the throughput of the line by 40% – from 1,200 bottles per hour to 2,000 – and Fillongley has reduced its gas consumption by about a third. 

“A reduction in gas consumption wasn’t something we set out to achieve, so this is a real bonus for the company and means the payback period for the bottling line is reduced.” says Martin. 

It is within the bottle washer that, via a heat exchanger, steam from Fulton’s VSRT vertical boiler is used to heat the detergent. The company also took the decision to retain the existing vertical steam boilers for duty-standby purposes.

The VSRT is the first steam boiler to emerge from Fulton’s new ‘PURE Technology’ approach, an initiative that’s resulted in a world-first design that is durable, long-lasting and boasts the highest efficiencies and ultra-low NOx emissions as standard. This new approach aims to enhance heat transfer, provide class-leading efficiencies, improve steam quality and reduce NOx emissions.

Rather than further-improve products like its J Series to achieve these goals, PURE Technology – the culmination of Fulton’s clean slate approach to design – challenges the industry status quo on conventional boiler design by engineering solutions that are fit-for-purpose and fully-optimised for all applications.

Launched in 2018, Fulton’s VSRT steam boiler is unlike anything the industry has seen before. And because of its radical, world-first design that is durable, long-lasting and boasts the highest efficiencies and ultra-low NOx emissions as standard, it’s also catching the eye of those judging product and innovation awards.

At the recent Institute of Gas Engineers and Managers’ (IGEM) Gas Industry Awards 2019 at the London Hilton on Park Lane, Fulton’s VSRT continued its winning streak by claiming the Product of the Year award, the vertical steam boiler’s third award in six months.

Commenting for Fulton, managing director Carl Knight says: “The double-award-winning VSRT becomes a multi-award-winning steam boiler and we couldn’t be more delighted with this Product of the Year award. It was up against some stiff competition, which we hope proves just how impressive this next-generation boiler is and how much hard work has gone into developing the VSRT.”.

With over 15 patents pending in three continents, the VSRT’s spiral-rib heat exchanger is a world first. It attains industry-leading heat transfer rates thanks to its unique spiral design, which achieves low stack temperatures by passing the flue gases through a spiral-wound heat exchanger that is fully immersed in water. 

“The PURE Technology approach adopted for the VSRT aims to enhance heat transfer, provide class-leading efficiencies, improve steam quality and reduce NOx emissions.” says Carl. “Rather than simply try to improve existing products to achieve these goals, PURE Technology challenges the industry status quo on conventional boiler design by engineering solutions that are fit-for-purpose and fully-optimised for all applications.”.

Fulton is delighted to confirm that its VSRT Steam Boiler Operation & Maintenance course has been certified by the CPD Certification Service as conforming to the continuing professional development principles. 

The news follows the company’s announcement in late-2018 that it had achieved similar CPD Certification status, but for its Vertical Steam Boiler Operation & Maintenance course.

Commenting for Fulton, aftercare and business development manager Jeff Byrne says: “You could be forgiven for thinking that achieving certified status for the VSRT course was easy as we had recently achieved similar for our vertical steam boiler course. However, given the radical design of our double-award-winning VSRT steam boiler and the fact that it was only launched in early-2018, it took months of extra assessments to achieve. We are therefore delighted to have gained certification for the training course so quickly.”

Designed for boiler operators, the one-day VSRT Steam Boiler Operation & Maintenance course covers basic monitoring and day-to-day operation of steam boilers to provide employees with the knowledge required to ensure boilers are running safely and efficiently. It also focuses on the VSRT’s use of state-of-the-art controls and technology, looks in-depth at its patented spiral heat exchanger and includes training in operational procedures, daily blowdowns and the checking of water levels, alarms, etc. Finally, it examines the importance of correctly treated feedwater and what boiler inspectors will look for during routine insurance inspections.

Further information on Fulton’s training courses can be found on their website, by calling +44 (0)117 972 3322 or emailing training@fulton.co.uk.

The claims made by vertical steam boiler manufacturers are easy to get excited about, especially at a time when stringent industry and environmental standards – such as the MCPD and London’s Air Quality Strategy – are making the headlines. Fulton’s Carl Knight takes a closer look.

We’ve all read the claims, “class-leading”, “energy efficient”, “superior steam quality”, “low maintenance”, the list goes on. But do these claims really stack up?

There are really only two vertical tubeless steam boiler solutions available in the UK. One is based on decades-old technology and the other is Fulton’s all-new, award-winning VSRT, a ground-up, clean-slate design approach that combines new people with new skills that have brought a new approach to the design and optimisation of heat transfer solutions.

And yes, Fulton has its own claims to make: that the VSRT is the most radical change to vertical steam boiler design since they pioneered the vertical tubeless boiler in 1949.

But let’s look at some of these claims in more detail and base the findings on Fulton’s VSRT-60 compared to equivalent 60HP vertical tubeless steam boiler models available in the UK.

Energy Efficiency
With full operating performance curves available throughout the full range of output – and at various operating pressures – Fulton’s VSRT provides exceptionally high operating efficiencies (84% gross thermal efficiency compared to approximately 80% from equivalent models), which result in lower operating costs.

These operating efficiencies are achieved thanks to the VSRT’s long heat transfer path and double-wall annular spiral rib heat exchanger that are fully-water-backed. This means that heat is transferred in two directions to double the heat transfer area in a fixed volume. The fully-water-backed design of the VSRT also allows low jacket loses which, combined with low flue gas temperatures, provides the highest thermal efficiencies.

Its combustion technology – featuring a Fulton-designed modulating burner and furnace that have been designed as a single component and fully-matched with the VSRT in mind – has also helped Fulton to achieve ultra-low NOx emissions of less than 20ppm and up to 10:1 turndown capability. Additionally, when correctly sized for applications, the exceptionally high turndown of the VSRT will result in savings above and beyond those gained from the stated efficiencies.

Steam Output & Quality
At 1,306 litres, the water volume of the VSRT-60 is almost 120% greater than equivalent 60HP vertical tubeless steam boilers yet, despite the increased volume, the VSRT still boasts a start-up time of 10-15 minutes and its installed footprint is up to 25% smaller. At 8 bar, the VSRT also achieves a 99.75% steam quality, a figure most manufacturers are unwilling to publish.

Durability & Warranty
Thanks to its down-firing burner alignment – that eliminates flame impingement on the pressure vessel – and the VSRT’s patented spiral-rib heat exchanger design that virtually eliminates thermal stress, Fulton has created a longer-lasting boiler that not only improves boiler efficiency, but one that the company believes will beat the competition in every category of durability. This is why all VSRT models come with the assurance of a 10-year “unparalleled” warranty on the pressure vessel, double that of the industry standard.

Maintenance
With features including a tubeless design, no internal refractory and a revolutionary air filtration system as standard, the VSRT is extremely easy to maintain. For applications where contaminated air can reduce boiler uptime, the VSRT’s standard-fit cyclonic air filter effectively separates debris and damaging particles from the combustion air and, because it won’t clog over time, eliminates the need for replacement filters.

Compared to other tubeless vertical steam boilers, maintenance is further improved thanks to the VSRT’s industrial control platform and easy access to the pressure vessel.

In Summary
All the advanced, energy-saving and environmentally-beneficial features mentioned above are standard across the VSRT range, which is currently available with outputs from 160 to 960 kg/h. Fulton is also developing a much larger VSRT-250 model – planned for early 2019 – with a steam output of approximately 4,000 kg/h, similar to that offered by manufacturers of horizontal steam boilers.

Compared to equivalent 60HP vertical tubeless steam boilers, the VSRT is a more durable, compact boiler that is energy-efficient, produces an increased volume of higher quality steam, is easy to maintain and backed by an unparalleled warranty. Additionally, the VSRT complies with the City of London Air Quality Strategy and anticipated MCPD regulations, is constructed to BS EN 12953 and CE marked to PED.

So, before committing to a tubeless vertical steam boiler for your next heat transfer project, consider the “class-leading” claims about energy efficiency, performance, reliability and maintenance and instead look at the figures that speak for themselves!

For further information on the VSRT, call Fulton on 0117 972 3322, email sales@fulton.co.uk or visit www.fulton.co.uk.

The VSRT from Fulton – the company’s all-new vertical spiral-rib tubeless steam boiler – already boasts ultra-low NOx emissions and high efficiencies, but now comes with a 10-year “unparalleled” warranty on the pressure vessel, double that of the industry standard.

Commenting for Fulton, sales and marketing manager Leigh Bryan says: “The unique spiral-rib design of the VSRT creates a longer-lasting boiler that we believe will beat the competition in every category of durability so, to put our money where our mouth is, we have decided to include a 10-year warranty on the pressure vessel as standard!”

The patented spiral-rib heat exchanger design – a result of the company’s ‘Pure Technology’ approach to systems engineering – not only allows Fulton to improve boiler efficiency but, with virtually zero thermal stress and a thick-walled construction featuring vertical tubeless design architecture, the VSRT is one of the most durable steam boilers available.

The VSRT is available with outputs from 160 to 960 kg/h and boasts ultra-low NOx emissions of less than 20ppm that are achieved thanks to its purposely-designed combustion technology. This has helped Fulton to achieve up to 10:1 turndown capabilities, an industry-leading performance of >82.5% gross thermal efficiency and 99.75% steam quality at 8 bar. It also complies with the City of London Air Quality Strategy and anticipated MCPD regulations, is constructed to BS EN 12953 and CE marked to PED.

Having recently rationalised its product range to ensure its solutions meet the requirements of the MCPD, Fulton announced that production of its horizontal reverse-flame boilers has ceased. However, the company can confirm that a much larger VSRT model with a steam output of approximately 4,000 kg/h – similar to those of its legacy RB horizontal steam boilers – is planned for early 2019 and will benefit from the same 10-year warranty on the pressure vessel.

For further information on the VSRT Series, call Fulton on +44 (0)117 972 3322, email sales@fulton.co.uk or visit www.fulton.co.uk.

Having introduced its City & Guilds accredited training courses four-and-a-half years ago, Fulton is delighted to announce that, following months of hard work and assessments, its Vertical Tubeless Boiler Operation & Maintenance training course has been certified by the CPD Certification Service as conforming to the continuing professional development principles.

Commenting for Fulton, aftercare and business development manager Jeff Byrne says: "Fulton has always enjoyed promoting the benefits of operator training to its customers and this CPD Certification adds real value to our course offering.”

Having achieved CPD status for its Vertical Steam Boiler Operation & Maintenance course, Fulton is now working towards certification for its VSRT Boiler Operation & Maintenance course which, given the radical design of the boiler, focuses on the VSRT’s use of state-of-the-art controls and technology and looks in-depth at its patented spiral heat exchanger. This all-new boiler design has emerged from Fulton’s adoption and implementation of its Pure Technology approach, an initiative that resulted in a world-first design that is durable, long-lasting and boasts the highest efficiencies and ultra-low NOx emissions as standard.

The Vertical Steam Boiler Operation & Maintenance course is designed for boiler operators and covers basic day-to-day operation and monitoring of steam boilers. It provides employees with the knowledge required to monitor boilers and ensure they are running efficiently and safely. The course also includes training in operational procedures, daily blowdowns and the checking of water levels, alarms, etc; as well as examining the importance of correctly treated feedwater and what boiler inspectors will look for during routine insurance inspections.

Training is also proven as being invaluable to employers and gives operators the knowledge and ability to handle more of their own maintenance and repairs and avoid call-outs to ‘boiler breakdowns’ that require no more than the simple flick of a switch to resolve. Real examples like this prove that a Fulton one-day Operator Routines & Maintenance course could potentially save the cost of many expensive and unwanted engineers’ visits.

Further information on Fulton’s training courses can be found on their website, by calling +44 (0)117 972 3322 or emailing training@fulton.co.uk.