Targeted infrared heating and intelligent control for a previously unheated industrial facility
Panalux operates a 63,000 sq ft specialist facility in Hayes supporting the film and television industry, with departments dedicated to lighting, grip equipment, cables, textiles, generators and equipment preparation.
When the facility opened, the large warehouse had no existing heating system. With no windows, limited insulation and extensive open working areas, temperatures could become extremely uncomfortable during the colder months.
Panalux needed an efficient heating solution that could provide warmth across individual workstations and operational areas without attempting to heat the entire volume of the building.
Following a detailed assessment of the facility, Shadow Industrial designed a targeted infrared heating system comprising 24 infrared heaters in various kW outputs, including 10 Shadow Horizontal Industrial Heaters and 14 Shadow Infinity Infrared Heaters. The installation was supported by the ShadowSmart control system, providing greater control over how and when heating is used throughout the facility.
The size, layout and day-to-day operation of the Panalux facility presented several challenges.
With large open spaces and high ceilings, a conventional heating system would need to heat a significant volume of air before employees at ground level felt the benefit. Frequently opened shutters and loading areas would also allow warmed air to escape.
Employees work across a variety of departments, from fixed computer stations and repair benches to equipment preparation, loading and distribution areas. This meant heating requirements could vary considerably throughout the building.
The heating solution also needed to work within the constraints of the building's EPC approval, making the specification and overall energy performance of the proposed system important considerations.
Gas-powered warm-air heating was considered, but there were concerns around heat distribution and the potential cost of heating such a large industrial space.
Panalux therefore needed a solution capable of:
Following the site assessment, Shadow Industrial specified a combination of Shadow Horizontal Industrial Heaters and Shadow Infinity Infrared Heaters, with different kW outputs selected to suit the requirements of individual areas throughout the warehouse.
The complete installation consisted of:
This provided a total of 24 infrared heaters, strategically positioned across the facility to provide targeted warmth within key working areas and departments.
Rather than relying on a conventional system to heat the entire volume of air within the warehouse, the infrared heaters deliver radiant warmth directly towards people and surfaces within their coverage areas.
This approach is particularly suited to Panalux's working environment, where employees may spend extended periods at workstations, repair benches and equipment preparation areas. It also provides an effective solution for areas close to loading bays and frequently opened shutters, where warmed air from a conventional system could quickly escape.
The different heater outputs allowed the system to be tailored to each location, taking into account factors such as mounting height, available space, working patterns and the level of heat required.
The installation was integrated with the ShadowSmart infrared heating control system, giving Panalux greater control over when and where heating is used.
Employees can activate heating serving their working areas using local push-button controls, while the central ShadowSmart system provides overall management. Timed operation allows the heating to automatically switch off after a set period, helping prevent heaters from being left running unnecessarily.
During warmer periods, the heating system can also be disabled centrally, preventing individual heaters from being activated when heating is not required.
To ensure the heating solution would fully meet Panalux's operational needs, the Shadow Industrial team conducted a detailed site survey.
By visiting the facility and engaging directly with the Panalux team, we were able to assess the unique demands of the space, including machinery clearances, workflow patterns, building construction, departmental requirements and specific employee comfort needs.
The survey also helped identify areas where staff remained stationary for extended periods, as well as locations affected by loading operations and frequently opened shutters.
This collaborative approach allowed us to specify the most suitable combination of Shadow Infinity and Shadow Solace heaters and develop a tailored heating layout around how the building is actually used.
The ShadowSmart control strategy was also designed around Panalux's operational requirements, combining central management with straightforward local control for individual departments.
By considering the building, its people and its working patterns as part of the specification process, the system could be designed to deliver effective heating, practical control, safe positioning and efficient use of energy.
After approximately two years of operation, the Shadow heating system has transformed working conditions within the previously unheated facility.
Employees now have access to targeted warmth throughout key working areas, with the rapid response of infrared heating allowing them to feel the benefit without waiting for the entire warehouse to warm up.
The combination of local push-button operation and ShadowSmart central control also means heating can respond to the different requirements of individual departments. Staff can activate heat when required, while timed automatic switch-off helps prevent unnecessary operation.
The system complements Panalux's wider approach to energy efficiency. The facility has an A-rated energy performance and rooftop solar panels that generate electricity for the building, with surplus generation capable of being exported back to the grid.
Using electric infrared heating alongside onsite solar generation provides Panalux with a practical alternative to introducing a gas-fired heating system, while targeted heating and intelligent controls help ensure energy is directed towards the areas where it is needed.
The completed installation delivers a flexible combination of employee comfort, targeted infrared warmth and intelligent heating control providing an effective solution for a large industrial building that previously had no heating at all.
Most companies today want to reduce or eliminate their net contribution to greenhouse gasses - but it can be hard to know where to begin.
What will have the most impact? One focus area for many organisations is their energy use and heating.
Gas-based systems are falling out of favour as they generate significant carbon emissions. Instead, many are turning to electric infrared heating as this offers the potential for zero emissions at the point of use if renewable energy is used to power them.
Infrared is a popular choice as it offers very high-efficiency ratings - up to 98% of energy is converted into heat. Additionally, heat isn't wasted as it can be focused on the areas that need it the most.
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