For technical directors, boiler operators and energy consultants
Physics, not promises.
You have seen plenty of efficiency miracles. So no marketing copy here — just the working principle, the scientific reports, the measurement method and the limits of the technology. On request: a direct call with our technician, no sales people.
The working principle in two minutes
Recording coming soon
The working principle
High-temperature ceramic elements are positioned in the boiler's flame tube. In operation they heat up to 1,000–1,200 °C and glow white. The emissivity of the ceramic is around 0.95 — boiler steel sits at around 0.25. The ceramic thus converts a substantial share of convective heat into infrared radiation acting directly on the water-side surfaces.
The second, often larger lever is the heat-store effect: the ceramic absorbs flame energy the boiler itself cannot hold and releases it during burner pauses and part-load phases. Cycling plants restart considerably later; modulating burners run at a lower stage thanks to the larger heat-transfer surface. 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 ceramic additionally prevents the chimney draught from cooling the boiler.
The starting point becomes visible when you place side by side the three efficiency figures quoted for the same boiler:
Made to measure, not off the shelf
Every ceramic set is matched to the flow and combustion-chamber geometry of the specific plant. The layout is worked out to the millimetre — the structural integrity of the boiler stays untouched.
The tailoring extends to the material itself. A system of three different ceramic types is used, each with its own composition, matched to the different thermal loads at their positions inside the boiler: the shaped blocks at the flame point carry different loads than the bars of the substructure.
Where the difference goes
Between the energy you pay for and the heat that arrives lie 20 to 40 percent. They are lost through flue-gas heat and through the start-up and cool-down phases — a flue-gas measurement on a running burner sees neither.
Validation
- ■GWI Essen (Gas and Heat Institute), CFD simulation: ~18 percent more heat transferred to the water side, flue-gas temperature −62 K, heat-flux density safely below the EN 12953-3 limit.
- ■Expert report TU Clausthal: up to 20 percent savings on standard boilers, ~10 percent on condensing boilers.
- ■Long-term measurement at a German corporation 2019–2021: over 500,000 data points, ~10–12 percent better than the identical reference boiler without ceramic.
- ■Anonymised measurement protocol 2022 (Viessmann Vitoplex 300): +11.78 percent efficiency against an 8 percent forecast; CO −25.3 percent, NOx −23.1 percent.
We provide all reports and protocols in full in the technical call.
The measurement method (the real argument)
Consumption is measured before and after installation using a method developed together with TÜV — two to three hours per measurement under comparable load, designed for flow temperatures up to 110 °C. Should the system ever not reach its forecast, you choose between renegotiation and complete removal with a refund of the purchase price within seven working days. In the end, only the measurement on your own boiler counts.
Application range and limits
- ■Boiler output: approx. 150 kW to 30 MW.
- ■Boiler types: warm-water, hot-water, steam and thermal-oil boilers; gas and oil fuels.
- ■Requirement: horizontal forced-draught burner.
- ■One-day installation, no structural work; no permits required for hot-water boilers.
- ■Material: high-temperature ceramic rated for applications up to 1,650 °C, compressive strength 70 N/mm²; quality test: 30 times white-hot into cold water without any change to its properties. Maintenance-free, transferable to a new boiler.
- ■No electronics, no changes to burner, controls or water side — the boiler's approval status remains unchanged (steam boilers: coordination with the boiler inspector is organised).
Side effect for existing plants
Improved combustion cuts CO by ~21 and NOx by ~24 percent (averages of the reference measurements). Older boilers failing emission limits often return to compliance — extending the economic life of the existing boiler instead of forcing a replacement.
Book an appointment
Pick a free slot for a 15-minute call — we will ring you at the time you choose. The confirmation arrives by e-mail straight away.
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Frequently asked questions
›Does the ceramic change furnace pressure or burner settings?
Sizing is boiler-specific by Intensatec; the geometry keeps combustion behaviour and heat-flux density within standard limits (GWI simulation, EN 12953-3). The burner is re-commissioned after installation as usual.
›What about load changes and cycling operation?
That is exactly where the biggest effect occurs: the storage mass smooths temperature peaks and maintains radiant heat across burner pauses — cycling plants restart later, modulating burners run at a lower stage. Proof from the latest measurement: burner runtime down from 205 to 105 minutes at the same heat delivered.
›How do I see the effect in my own figures?
In two values: first, the flue-gas temperature — as a rule of thumb, efficiency rises by about 0.65 percent for every 10 °C lower flue-gas temperature. Second, the annual utilisation rate: in reality many plants run at 60–80 percent, far below the ~87 percent of the standard test — exactly this gap from part load and cycling is what the heat store recovers. You can verify both yourself after installation.
›How is the permit situation documented?
For every project you receive a written declaration of conformity, signed by our technical director (Dipl.-Ing.): for warm-water boilers up to 110 °C flow temperature no additional TÜV or authority permit is required, and your boiler's type conformity remains fully intact after installation — the ceramics are inserted, not built in.
›Can I talk to an operator's technician?
Yes. On request we arrange a call with technicians at existing customers — engineer to engineer.