Questions & answers

Solid ceramic elements installed as heat storage in the flame tube of existing gas and oil boilers — rated for applications up to 1,650 degrees Celsius, with a compressive strength of 70 N/mm². As proof of quality, every element is dipped white-hot into cold water 30 times without any change to its properties. This is explicitly NOT a coating and not electronics: nothing that wears out, needs calibration or maintenance. In operation the ceramics glow white at 1,000 to 1,200 degrees, working as a radiation converter and energy store.

Four effects work together. First: the ceramics swirl the combustion gases and guide them closer to the water-side chamber walls — heat transfer increases, cold zones and possible condensation are avoided. Second: the white-hot ceramics radiate infrared heat with an emissivity of 0.95 — bare boiler steel only reaches 0.25. Fuel is converted into usable heat more evenly and completely. Third: the ceramics store flame energy and release it during burner pauses — the boiler cools more slowly and restarts as if warm-started. Fourth: air staging and longer gas residence time reduce nitrogen oxides, carbon monoxide and soot. The biggest lever is the heat-store effect: cycling plants restart considerably later, and modulating burners run at a lower stage thanks to the larger heat-transfer surface — like a car doing 80 km/h in fifth gear instead of fourth.

The standard flue-gas test only measures while the burner runs — and modern boilers are indeed good there. What it does not show: how much usable heat your boiler actually delivers per cubic metre of gas, across restarts, part load and pauses. That is exactly where the heat store works — which is why it even works on condensing boilers at 99 percent efficiency: at an automotive branch, 19.69 percent more energy yield per cubic metre of gas was measured on precisely such a boiler. The effect never shows in a standard test, but it does show in the before/after protocol and on the gas bill.

Warm-water, hot-water, steam and thermal-oil boilers with a horizontal forced-draught burner, from approx. 150 kilowatts to 30 megawatts. Fuels: natural gas, biogas, heating oil, heavy oil and vegetable oil. Plants without a horizontal forced-draught burner are not suitable — we clarify this in the first call from a photo of your plant within minutes.

The CFD flow simulation by Gaswärme-Institut Essen (FLUENT) showed: heat-flux density stays safely below the EN 12953-3 limit — installation is thermally safe. Confirmed in practice: zero damage claims since 2016, confirmed in writing by the business liability insurer (Allianz). Nothing is changed on the burner, the controls or the water side; the burner is re-commissioned normally after installation.

The elements are transferable: if the boiler is replaced later, they move into the new plant and keep saving. The investment is not tied to the current boiler's lifetime. Often the ceramics even postpone replacement by years — older plants frequently return below the regulatory emission limits thanks to cleaner combustion.

Yes, two: for every 10 °C lower flue-gas temperature, efficiency rises by about 0.65 percent — the ceramics lower the flue-gas temperature because more heat stays in the boiler instead of going up the chimney. And: the real annual utilisation rate of many plants is only 60–80 percent, far below the ~87 percent of the standard test — exactly this gap from part load, cycling and pauses is what the heat store recovers. Your engineers can check both values on your own plant.

Reference projects measured 10 to 17 percent less fuel consumption — depending on the sector: hospitals and care 14.2 percent, hotels and spas up to 16.3 percent, industry and manufacturing up to 17 percent, food industry 11 to 14 percent, laundries 11 to 15 percent. Important: the forecast in your quotation is deliberately conservative — in documented measurement series across more than 25 industries it was consistently exceeded. Two examples: on a Viessmann Vitoplex 300 the forecast was 8 percent, the measurement showed 11.78 percent; at a hospital in July 2026 the forecast was 12 percent, the measurement showed 15.22 percent.

With a method developed together with TÜV, in two measurement runs: once in your boiler's original state and once after the ceramic is installed — with identical instruments, in normal operation, in just 2 to 3 hours. The difference (the “delta”) is measured, so instrument inaccuracies barely matter; for safety we also apply a ±5 percent buffer. The method is designed for flow temperatures up to 110 °C. A real example: on a warm-water boiler the forecast was 8 percent, the measurement showed 11.78 percent — still 11.19 percent even with the least favourable safety margin.

Two independent institutes: the thermodynamic expert report by TU Clausthal shows savings in the region of 20 percent for boilers using the lower heating value and around 10 percent for condensing boilers. The CFD flow simulation by Gaswärme-Institut Essen (FLUENT) confirms roughly 18 percent higher heat transfer to the water side at a heat-flux density safely below the standard limit. Add a long-term measurement by a major German corporation (2019 to 2021, over 500,000 data records): identical boilers in direct comparison, 12.1 percent better result with ceramics against a 10 percent forecast, constant over two years. Details on the science page.

We know that reflex — and we share it. So the measurement on your own boiler decides, before and after. In 100 percent of documented projects so far, the forecast given beforehand was exceeded; in one case in the timber and health sector, 34 percent was measured against a 10 percent forecast, TÜV-documented. And should the forecast ever not be met, the performance guarantee applies: renegotiation of the terms or complete removal with a refund of the purchase price. Your risk is therefore zero — waiting, on the other hand, costs you: €3,000 to over €10,000 per month depending on the plant.

Then you choose: either we renegotiate the terms, or the system is completely removed — in which case we refund the invoiced amount within seven working days. The decision is yours. The measurement alone decides. For context: since market launch in 2016 there have been zero damage claims, confirmed by Allianz Versicherungs-AG.

Several hundred plants since 2016, sold almost entirely through personal referrals — including international corporations, leading hospital groups, breweries, hotels and industrial companies. You'll find a selection of names, plus the anonymised forecast-vs-result comparison across all industries, on the home page and on the references page with real installation photos.

Fair question — the answer is unspectacular: we did practically no advertising until 2026. Several hundred plants were sold almost entirely by operator-to-operator referral. That is changing now: the market is being developed systematically. The physics has been scientifically studied since 2011 — you can read the expert reports, and verify everything with the before/after measurement on your own boiler.

Installation takes a single day, inside your plant's planned maintenance window. Trained technicians deliver the elements and position them in the flame tube — plug and play, without structural changes to the boiler system, without touching the burner, controls or water side. We prepare all required permits. Afterwards the burner is re-commissioned normally and the plant returns to regular operation.

No. Installation is scheduled into a maintenance or overhaul window that is planned anyway. Sites with redundant boilers (such as hospitals) simply run on the second unit meanwhile. The before/after measurement also happens during live operation — the retrofit causes no production downtime.

Very little — by design. It starts with about ten minutes of data collection: photos of the type plate and the plant plus consumption data, via WhatsApp if you like. Everything else — sizing, quotation, permits, installation planning, measurement — is handled by us. Your only other commitment is the maintenance window for installation day.

No. The elements are maintenance-free for their entire life — no electronics, no moving parts, nothing to calibrate, no wear in normal operation. The exceptional thermal-shock resistance is proven by the 30-fold quench test of every element. There are no running costs.

Nothing changes in the process or the plant's certification — there is no water-side intervention and no change to the pressure body. Heat-flux density demonstrably stays within the standard limits (EN 12953-3, GWI simulation). The spotless operating history since 2016 — zero damage claims — is confirmed by the business liability insurer (Allianz). We prepare any required permits for you.

The investment depends on boiler size and plant configuration and is stated in your individual quotation — together with the binding savings forecast and the payback calculation, so you see cost and benefit side by side in writing. Your quotation arrives within seven working days. For orientation: payback is typically well under 2 years, in many cases under one year; the documented best case was 0.54 years (hospital, July 2026). And the risk is covered by the performance guarantee: should the forecast ever not be met, you choose between renegotiation and complete removal with a refund of the invoiced amount.

Typically well under 2 years, in many cases under one year — in the documented best case after 0.54 years (hospital, July 2026: measured 15.22 percent, €118,890 saved per year). Further examples: 0.65 years on a Viessmann Vitoplex 300 (11.78 percent, €35,703 per year); a major corporation's long-term measurement showed 1.3 years — calculated at the very low gas prices of that time; at higher energy prices payback shortens accordingly. After that, the plant keeps saving year after year, maintenance-free.

Every kilowatt-hour saved directly cuts your CO₂ emissions — and your carbon-pricing costs: currently €55 per tonne, from 2028 via the European emissions trading scheme (ETS 2) with prices expected to rise. Carbon dioxide falls exactly as far as fuel does — by 10.5 percent in the 2022 reference protocol and by 13.21 percent in the 2026 hospital project. The carbon that goes in comes back out; more is not arithmetically possible. Better combustion adds: carbon monoxide minus 25.3 percent, nitrogen oxides minus 23.1 percent. For ESG reports and energy audits, the retrofit delivers an immediately documentable contribution.

The most honest calculation: without the retrofit, a boiler with a typical consumption profile loses 3,000 to over 10,000 euros per month in avoidable fuel costs, depending on size. The calculator on this website shows your number in 60 seconds — anonymous and without obligation.

Intensatec develops, manufactures and installs the ceramic heat storage — made in Germany, in service in several hundred plants since 2016, from international corporations to leading hospital groups, with zero damage claims (confirmed by Allianz). Felix Scheffel is your personal contact: he accompanies every project from the first call through data collection to the verification measurement on your boiler.

Five steps: first, contact and boiler data — you complete the data capture in ten minutes (type plate, plant photo, consumption). Second, your individual quotation with savings and payback calculation, within about 7 working days. Third, one-day installation in the maintenance window. Fourth, the before/after measurement using the method developed together with TÜV, 2 to 3 hours during live operation. Fifth: you save — backed by the money-back guarantee. Typical total time from first call to running savings: four to eight weeks.

Three ways: by phone at +43 681 10137201 (Austria) or +49 89 12301067 (Germany), via WhatsApp on +43 681 10137201 — ideal for photos of your plant — or by e-mail to info@intensatec.at. If you prefer structure: the savings calculator (60 seconds, anonymous) and the data form (10 minutes) are the most direct routes to a concrete quotation. Your personal contacts with direct lines are listed on the contact page.

No. First call, savings calculation and quotation are free and without obligation. There is no closing pressure — the removal guarantee makes persuasion unnecessary, because in the end the measurement on your boiler decides anyway. An enquiry risks exactly ten minutes of your time.