INTENSATEC high-temperature ceramics
Intensatec high-temperature ceramics retrofit existing gas and oil boilers and make them measurably more efficient — one-day installation, no structural work, payback typically well under 2 years, in many cases under one year. For warm-water and hot-water boilers, every quotation includes a guaranteed minimum saving. For steam boilers, an individual thermodynamic potential analysis is carried out. The subsequent measurement on your boiler has confirmed and exceeded our forecasts in every single project so far.
Validated by
TU Clausthal
Gaswärme-Institut Essen
Image sequence generated using artificial intelligence.
10–17 %
measured fuel savings
150 kW–30 MW
boiler output — gas, oil, thermal oil
0
damage claims since 2016 — confirmed by Allianz
2–3 hrs
to proven savings during live operation
🤖 Some visual scenes in this video were generated using artificial intelligence.
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The high-temperature ceramics work in the background of critical infrastructure — in the boiler plants of global automotive groups, international hospital networks, leading breweries and listed companies. Documented and proven across more than 25 industries.
Industry groups
In 100 % of documented cases the real savings in live operation exceeded the conservative forecasts. Validated across more than 25 industries — from pharma logistics to heavy industry.
Automotive · metal processing · sheet-metal work · forming technology · industrial groups · building components · manufacturing
10.43 %
Ø forecast
15.43 %
Ø measured
Hospitals & health · pharma logistics · medical and dental technology
9.33 %
Ø forecast
14.20 %
Ø measured
Food & industrial bakeries · consumer goods · textiles · chemicals and paints · wood processing
11.20 %
Ø forecast
18.36 %
Ø measured
Hospitality · spas and public pools · health & fitness
9.67 %
Ø forecast
15.34 %
Ø measured
Energy supply · wholesale and logistics · facility management · telecommunications · media & broadcasting
10.60 %
Ø forecast
15.86 %
Ø measured
The starting point
Heating and steam boilers are needed across the board for a wide range of applications. They are among the very largest energy consumers in industry and commerce — and therefore also the most powerful lever for cutting energy costs immediately and measurably. Many plants run far less efficiently than their operators assume — and the cost of that rises year after year.
A boiler absorbs only part of the flame's energy immediately — the rest is lost through flue gas and cooling phases. Exactly this energy is captured by the glowing ceramic store and released when the burner pauses or runs at part load.
Carbon pricing makes every tonne more expensive by design: currently €55 per tonne, and from 2028 the European emissions trading scheme (ETS 2) takes over — with prices expected to keep rising. Every kilowatt-hour not burned protects you twice.
Instead of tying up valuable capital prematurely, a targeted retrofit optimises the efficiency of your existing plant. You secure compliance with regulatory limits, extend the economic service life of your boiler and gain time and financial headroom for your future energy roadmap.
The solution
Intensatec HTC stands for High Temperature Ceramics: ceramic high-temperature heat-storage elements placed inside the combustion chamber of existing boilers. They optimise combustion, improve heat transfer and store energy the boiler alone cannot hold — for burner pauses and part load.
The ceramics are rated for applications up to 1,650 °C, with a compressive strength of 70 N/mm². As proof of quality, each element is dipped white-hot into cold water 30 times — without any change to its properties. The result is a maintenance-free heat store with exceptional thermal-shock resistance, in continuous service since 2016.
How it works
Inside the combustion chamber, the high-temperature ceramics act like an energetic catalyst — changing the boiler's flow, radiation and heat storage at the same time.
The ceramics swirl the combustion gases and guide them closer to the chamber walls behind which the water circulates. Cold zones — and possible condensation — are avoided, and heat transfer increases.
The white-hot ceramics radiate heat with an emissivity of 0.95 — compared with 0.25 for bare steel. This converts the fuel into heat more evenly and more completely.
The ceramics store the flame energy and release it as radiation during burner pauses. The boiler cools down more slowly and returns to operating temperature faster on restart — like a warm start.
The longer residence time of the gases (air staging) reduces NOₓ formation. The improved combustion also prevents CO from rising and soot from forming.
The ceramics store flame energy the boiler itself cannot absorb — and keep working with it while the burner rests. When the burner switches off, the glowing ceramics keep the boiler warm far longer, so it needs to restart much later. And when the burner modulates, the larger heat-transfer surface lets it run at a lower stage for the same heat — like a car doing 80 km/h in fifth gear instead of fourth: same speed, less fuel. In the latest hospital measurement (July 2026), burner runtime fell from 205 to 105 minutes for the same heat delivered. On plants whose flue path stays open during pauses, the glowing ceramics additionally prevent the chimney from cooling the boiler down.
Independently confirmed
The effectiveness of the high-temperature ceramics is documented in expert reports, simulations and university studies — by two independent institutes.
up to 20 %
Institute of Energy Process Engineering and Fuel Technology
The thermodynamic expert report shows: boilers using the lower heating value almost invariably achieve energy savings in the region of up to 20 % with Intensatec HTC — condensing boilers around 10 %.
10–15 %
GWI e.V. — numerical CFD flow simulation (FLUENT)
The simulation confirms roughly 18 % higher heat transfer to the water side. The heat-flux density stays safely below the EN 12953-3 limit — installation is thermally safe.
Our principle
Mathematics doesn't lie.
We deliver measurable results. Every figure on this page comes from an expert report, a measurement protocol or a documented project — and every single one is verifiable.
Facts and figures
What counts is measurement during live operation — partly using the measurement method developed together with TÜV, partly with the client companies' own engineers.
In 100 % of documented cases the forecast given beforehand was exceeded by the later measurement — because we deliberately calculate conservatively.
Two measurement runs before and after installation, identical instruments, normal plant operation — with near-identical measurement cycles on both days to guarantee absolute comparability of the data. The forecast was 13 %. The measured reduction in primary energy was
17.02 %
This resulted in the technology paying for itself after just 0.78 years. Technically supervised by Dipl.-Ing. Wolfgang Gschwender.
Emissions in the same measurement run
−17.02 %
Carbon dioxide (CO₂)
−30.98 %
Carbon monoxide (CO)
−17.22 %
Nitrogen oxides (NOₓ)
Measured before and after on the same plant, with the same instruments.
Two warm-water boilers built in 1991: a measured 15.22 % efficiency gain, €118,890 saved per year, payback 0.54 years. Proof that older plants in particular benefit above average.
Measured on a modern condensing boiler already running at around 99 % efficiency — the ceramics still delivered 19.69 % more energy yield per cubic metre of gas. Payback: 1.23 years.
From automotive suppliers to industrial bakeries, hospitals, breweries and textile plants: in every documented measurement series the deliberately conservative forecast was exceeded — across all industries. The full forecast-vs-result comparison is on the references page.
A long-term measurement commissioned by a major German corporation (2019–2021) compared identical boilers with and without Intensatec HTC across more than half a million data records. Result: the 10 % forecast was consistently exceeded over two years, payback in 1.3 years — at the low gas prices of that time (3.87 ct/kWh).
Ecology & ESG
Every kilowatt-hour saved directly lowers CO₂ emissions — and with them your carbon-pricing burden. The optimised combustion measurably improves the plant's entire flue-gas behaviour.
Measured: −13.21 percent (hospital, July 2026) and −14.06 percent (automotive branch, April 2026) — a direct lever for ESG targets and carbon costs.
Measured: −23.68 percent (hospital) and −15.53 percent (automotive branch) — more complete combustion, documented in the measurement protocol.
Measured: −16.53 percent (hospital) and −8.46 percent (automotive branch) — fewer nitrogen oxides thanks to calmer combustion.
The measured CO₂ reduction can be transferred directly into your CSRD/sustainability report — including the measurement protocol as evidence. Additional effect: older boilers often return to flue-gas values below the regulatory limits — significantly extending their operating permit and service life.
Two installations, step by step
Every plant is documented for real: from the closed boiler through the empty combustion chamber to the finished ceramic installation — here two 2026 projects, a hospital and an automotive branch.
Zero risk
For heating boilers every quotation includes a guaranteed minimum saving; for steam boilers an individual thermodynamic potential analysis is carried out. The savings are verified in just 2 to 3 hours during live operation, using the measurement method developed together with TÜV — and so far the measurement has confirmed and exceeded our guarantees and forecasts in every single project. Should the target ever not be met, you choose: renegotiation of the terms or complete removal with a refund of the purchase price within 7 working days. Since market launch in 2016 there has not been a single damage claim — officially confirmed by Allianz Versicherungs-AG.
Business liability insurance of the manufacturer Intensatec with Allianz Versicherungs-AG.In five steps
You send us the type plates, a photo of the plant and consumption data — you complete the data capture in 10 minutes.
Within about 7 working days you receive a quotation with a savings and payback calculation.
Trained technicians deliver the ceramic elements and install them professionally. All permits are prepared.
Savings are proven in 2–3 hours during live operation — using the method developed together with TÜV.
Lower energy costs, less CO₂ — backed by the money-back guarantee for heating boilers.
Preset: 4.88 ct/kWh · Eurostat, Industriekunden ohne Steuern · Eurostat, 1. Halbjahr 2025
The range runs from the forecast INTENSATEC gave before installation to the result measured afterwards. The industry you pick changes the result noticeably — please choose the right one.
The heat store works hardest during burner pauses and part load. This answer shifts the result within the documented range — it rests on engineering judgement, not on a measurement of its own.
No. These are solid high-temperature ceramic elements (heat storage) positioned in the flame tube. No electronics, no burner or control changes, maintenance-free, transferable to a new boiler.
Warm-water, hot-water, steam and thermal-oil boilers with a horizontal forced-draught burner, approx. 150 kW to 30 MW, gas and oil.
Exactly — so the measurement on your own boiler decides: before/after, using a method developed together with TÜV. In 100 % of documented cases the forecast was exceeded — most recently in July 2026 at a hospital: 15.22 % measured against a 12 % forecast, payback 0.54 years. Should the forecast ever not be met, the performance guarantee applies: renegotiation or complete removal with a refund of the purchase price. Scepticism costs you nothing. Waiting does: €3,000 to over €10,000 per month.
Data collection 10 minutes, quotation in about 7 working days, installation in one day inside a planned maintenance window. Typically four to eight weeks from first call to running savings.
Intensatec — developed and manufactured in Germany, several hundred systems since 2016, customers from international corporations to leading hospital groups, zero damage claims, confirmed by Allianz. Felix Scheffel is your personal contact, from first call to verification.
