Ragus’ burner upgrade drives energy savings and resource efficiency

During 2024, Ragus completed a significant upgrade at its Slough factory, installing new burners and controls to our original steam boilers. This upgrade marks an important step in our ongoing commitment to resource optimisation and environmental stewardship, and aligns with our broader environmental, social, and governance (ESG) goals.  

Ragus has chosen to upgrade, rather than replace, its steam boilers as the boilers are well-built and remain in excellent working condition. This approach embodies our ESG principles, as by maximising the lifecycle of our equipment we minimise our environmental impact. 

Ragus’ existing boilers have been in operation for over 20 years, demonstrating exceptional durability and performance. Built to high standards, these steam boilers were designed with adaptability in mind and are already capable of utilising alternative fuels like hydrogen, aligning with the potential future shifts in energy policy towards greener options.

By choosing to replace the burners and controls rather than the entire boiler system, we are not only extending the lifespan of our existing equipment but reducing the environmental impact associated with manufacturing new boilers. This approach reflects a core principle of Ragus’ sustainability strategy: reuse and resource conservation. 

Regular maintenance has been key to the longevity of these boilers. Annual inspections support optimal performance and longevity. This proactive maintenance plan has been instrumental in extending the lifecycle of the boilers, and they could continue to operate efficiently for another 20 years or more. 

The decision to upgrade the burners and inverters was driven by a clear opportunity to improve energy efficiency and reduce resource consumption. Although state-of-the-art at the time of commissioning, the original burners operated on what by current standards is a simple, less efficient system: they were either running at 100% capacity or switched off entirely. This led to higher natural gas consumption, particularly during periods of lower demand.  

The new system features a variable-rate control, a major improvement that adjusts the burner output based on the current load on the boiler. This is achieved through the integration of advanced boiler controls, including high-precision probes and automated computer systems.  

These sensors continuously monitor the factory’s steam requirements, allowing the burners to modulate automatically, responding to real-time demand. Instead of operating at maximum capacity, the burners now typically run at 60-70% when full power isn’t necessary. This smart, demand-driven operation leads to substantial savings in both gas and electricity. 

The efficiency gains don’t stop there. The upgrade includes a fan system that adjusts speed according to the load on the boiler. The fan, a key part of the burner system, now optimises the gas flow into the boiler by modulating its speed based on steam demand. This reduces electricity consumption while enhancing overall process efficiency, leading to a significant reduction in both gas and power usage. 

Through these combined upgrades — variable burner output and automatic, load-responsive controls — we have achieved a twofold efficiency gain: reduced natural gas consumption and lower electricity usage. This is consistent with our broader sustainability objectives. 

A notable feature of our existing boilers is their capability to burn alternative fuels, including hydrogen. While the current fuel source remains natural gas, Ragus is looking ahead and preparing for a potential transition to hydrogen, in line with emerging national energy strategies.  

As governments worldwide begin to explore hydrogen energy, Ragus’ foresight in maintaining hydrogen-ready equipment demonstrates our commitment to sustainable innovation and future-proofing our operations.   

Ragus’ existing state-of-the-art factory, completed in 2012, was designed with efficiency at its core, featuring systems that minimise energy consumption and carbon emissions. The recent burner upgrade is part of an ongoing effort to achieve incremental gains in efficiency, reflecting our approach to continually refine processes rather than relying on drastic overhauls. 

While the factory is already highly efficient, these small improvements are crucial in helping us meet our CO2 reduction targets and reduce reliance on natural resources. By making targeted upgrades like the burner replacement, we are taking measurable steps towards more sustainable operations, reinforcing our commitment to all our stakeholders and the environment. 

Efficiency isn’t just about reducing costs; it’s about building a more sustainable future. The burner upgrade project is a testament to this commitment, showcasing our dedication to innovation, resource optimisation and responsible manufacturing. We continue to refine our processes, and these incremental changes will help drive our long-term vision of environmental stewardship and operational excellence. 

Ragus manufactures speciality syrups and crystalline sugars for use in industrial food and drinks applications. To learn more, contact our Customer Services Team. For more updates on Ragus’ sustainability initiatives and product innovations, continue browsing SUGARTALK and follow Ragus on LinkedIn.