Time to Upgrade Your Plant’s Heating System?

Jamie Tuinstra, Modine Manufacturing

Posted 3/25/2025

Industrial heating systems typically run somewhere between 15 and 20 years before they require replacement. The last thing any facility manager wants is for their heating system to go out just as winter weather rolls in, which makes it crucial to think ahead. For heating systems that are advanced in years or showing signs of mounting inefficiencies, it may be prudent to plan a preemptive upgrade.

Choosing an industrial heating system upgrade for any facility is a big undertaking—not only because it’s a major expense, but because it can have a long-tail effect on the facility’s energy efficiency as well as employee comfort. When looking for the best industrial heating system, several factors should be considered.

industrial HVAC system — *Image courtesy Nuno Almeida from Getty Images via Canva*

Assessing Facility Needs

When determining the right type of heating system upgrade for an industrial facility, the most significant factor of all is the facility’s size. Simply put, when seeking a system that will ensure a safe and comfortable work environment, assessing the facility’s cubic footage is a critical starting point. Knowing the cubic footage of the facility will help facility managers calculate the heating output (typically measured in British thermal units, or BTUs) needed to maintain a consistent temperature.

While size is an essential consideration, there may be other special needs of the facility that affect the choice of heating system. These special needs often relate to the facility’s scope and application. For example:

Temperature and humidity control. In some industries—such as food processing—regulatory compliance dictates strict temperature and humidity controls. It’s vital for facility managers to know the necessary temperature range and humidity levels so they can select a heating system that reliably meets them.
Ventilation needs. Ventilation may be necessary to ensure a high level of indoor air quality and to meet regulatory requirements for employee health and safety. Note that not all types of industrial heater require ventilation; oil- and gas-powered systems certainly do, but most electric systems do not.
Zoning requirements. In industrial facilities with a larger footprint, it’s often necessary to maintain different temperatures in different areas; for example, the production floor and the warehouse may have different needs for temperature control. In these cases, it’s important to invest in a system that can accommodate different temperature settings in different zones.

Anticipating Long-Term Costs

A new industrial heating system is inevitably going to have a substantia up-front cost; there’s no getting around that. However, some systems may provide a greater lifetime value, especially if they provide energy efficiency or more minimal maintenance requirements.

For example, consider that some models will be marked for a higher level of energy efficiency—especially those labeled with high Seasonal Energy Efficiency Ratios (SEER) or Energy Efficiency Ratios (EER). These models often have higher price tags on the front end but may help the facility curb its utility costs in the long run.

There are also a number of advanced technologies that can enhance a heating system’s energy efficiency. Heat recovery technologies capture excess heat produced in one zone, then use it to heat another. Meanwhile, variable speed technologies modulate heat output to demand, ensuring the system only works as hard as it needs to at any given moment. These and similar technologies can maximize the long-term value of a new heating system.

Many heating systems that come with energy efficiencies will also be eligible for tax rebates and other financial incentives. Some local utility companies offer incentives of their own. It’s always worth checking these incentives, which can mediate the initial cost of an industrial heating system.

When shopping for an industrial heating system upgrade, it’s also important to think about long-term maintenance costs. The best systems are easy to maintain, have readily available parts, are made with corrosion-resistant parts, and come backed by robust warranties and/or flexible maintenance plans.

Evaluating Installation Needs

For facility managers searching for the best industrial heating system upgrade, an additional point to consider is installation.

When installing a new heating furnace or pump, it’s important to ensure the proper ductwork is in place. If not, that means more involved installation, and potentially greater disruptions to the factory’s day-to-day operations.

Unit heaters are comparatively easy to install, often just needing to be mounted with simple brackets. Ventilation may be required for certain types of unit heaters, though not for electrical ones. Unit heaters can also be strategically placed to ensure the temperatures needed in different zones of the industrial space.

For the easiest installation, setting up space heaters may work—though only in the smallest spaces. Generally, space heaters will be better for temporary heating needs, or in areas of the building that have only the most limited seasonal heating needs.

Investing in Longevity and Performance

Sooner or later, every heating system requires replacement—but making early investments in condition monitoring and routine maintenance can go a long way toward extending a system’s lifespan and thus protecting the investment.

When seeking a new heating system, it’s helpful to seek condition-based monitoring technology, which relies on sensors to provide real-time data about a unit’s performance. This data can alert maintenance teams about when they need to clean ducts or take other steps to keep the heating system running smoothly—potentially averting major problems, maintaining efficiency, and lengthening the useful life of the system.

Additionally, maintenance teams can be proactive about preserving the performance of their heating system via regular visual inspections of pressure gauges and temperature controls; meanwhile, regularly cleaning and descaling equipment helps maintain adequate heat transfer.

Don’t Delay Heating System Upgrades

Industrial spaces require robust heating systems to safeguard employee wellbeing—and to maintain full regulatory compliance. For facility managers, this is an occasion to think proactively. As an existing system begins showing signs of slowing down, or simply reaches the end of its expected lifespan, start thinking about the ideal options for an industrial heating system upgrade.

Jamie Tuinstra

Jamie Tuinstra is a product manager at Modine Manufacturing. He has been in the heating and cooling industry for 25 years and with Modine for 16. At Modine, we are engineering a cleaner, healthier world. Building on more than 100 years of excellence in thermal management, we provide trusted systems and solutions that improve air quality and conserve natural resources. More than 11,000 employees are at work in every corner of the globe, delivering the solutions our customers need, where they need them. Our Climate Solutions and Performance Technologies segments support our purpose by improving air quality, reducing energy and water consumption, lowering harmful emissions and enabling cleaner running vehicles and environmentally-friendly refrigerants. Modine is a global company headquartered in Racine, Wisconsin (USA), with operations in North America, South America, Europe and Asia. For more information about Modine, visit www.modine.com.

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Time to Upgrade Your Plant’s Heating System?