Author: Chris Hutchinson

Big congratulations to two of our amazing team members on tying the knot!

It’s not every day we get to celebrate a love story that we have followed from the start here at Fairburn Heating Solutions. We’re absolutely delighted for you both and wish you a lifetime full of happiness, laughter, and plenty of fantastic moments together.

From all of us at Fairburn Heating Solutions – congratulations Mr & Mrs Harris!

Sean and Finlay travelled to France at the end of January to complete our first hydrogen commissioning project.  We were engaged by Comtherm for the work at the ArcelorMittal Mardyck steelmaking plant in Dunkerque.

ArcelorMittal is one of the world’s leading steel and mining companies, with steelmaking operations in 14 countries across the globe.  They are the largest steel producer in Europe with a strong commitment to reduce energy consumption and carbon emissions.

The ArcelorMittal operations in Dunkerque are amongst the largest steelmaking facilities in Western Europe, offering high value-added products and services, mainly to the automotive industry, but also to construction and packaging.

ArcelorMittal is working closely with the French Government to decarbonise its operations in France.

Sean first visited the site in December 2025 and the commissioning was completed in late January.  Working to the specifications provided by the equipment manufacturer, the commissioning went smoothly and all partners are happy that everything is working properly.

Commenting on the project, Craig Carr, Managing Director of Fairburn Heating Solutions said “It’s great to see the hydrogen training we undertook in 2024 and 2025 being put in to practice by Sean and Finlay.  As the emerging hydrogen economy grows, we are well placed to support more clients with this kind of work.”

Do you need advice on the pros and cons of switching to Hydrogen?  Speak to our team today.

Following the recent PDR & Field Service analysis reviews by the board at Fairburn for the Field Service Technicians , we are delighted to announce that Dan Williams has been promoted to Senior Process Gas Technician.

Dan has been with the company for over 11 years and has taken the roles and responsibilities of a Process Gas Technician to a fantastic standard. His alignment to our company values & support for both the Field Service Team and the office are exceptional.  Dan has worked tirelessly to achieve these goals over these years, with many late nights, working away on jobs, and professional job site project management that always supports the whole team to the best of his abilities.

Commenting on Dan’s prompotion, Craig Carr, Managing Director said “It feels great to be able to acknowledge Dan’s unwavering support for Fairburn and his colleagues with this promotion.  I’m sure Dan will continue doing what he does best for years to come, helping, supporting the whole team here at Fairburn. I for one am always happy to work under his ideas and plans on site, it goes much smoother than when I plan the day!”

Please join us in congratulating him on his achievements, well done Dan. We’re proud to have you here at Fairburn Heating Solutions Ltd.

Artificial intelligence (AI) is increasingly being discussed across many areas of engineering and manufacturing. While still an emerging technology in the field of process heating, AI has the potential to influence how commercial gas heating systems are designed, installed and maintained in the years ahead.

This article explores some of the ways in which AI could impact the wider industry — not as a description of current practice, but as a look at what might be possible in the future.

AI in System Design

AI can process vast amounts of technical data far faster than traditional methods, opening new possibilities for the design of burners, furnaces and associated systems.
For example, machine learning algorithms can analyse complex thermodynamic models, combustion characteristics and heat transfer dynamics to identify configurations that maximise efficiency. The result could be designs that deliver the dual benefits of cost savings and lower emissions.

AI-driven tools may also enable the rapid generation of bespoke heating system layouts, balancing performance, safety and energy use for each specific application. In materials selection, AI could assist in identifying alloys or refractories that minimise thermal losses and extend service life — further improving the long-term performance of heating equipment.

AI in Installation

In the future, AI-assisted design and planning tools could help engineers optimise the physical layout of process heating systems. Algorithms might evaluate burner positioning, flue routing and pipework runs to streamline installation and reduce on-site time.

Another emerging concept is the “digital twin” — a virtual replica of a system that can be tested and refined before any physical installation takes place. By identifying potential clashes or performance issues in advance, digital twins can reduce commissioning time and risk.

Looking further ahead, AI-powered robotics could also play a role in assisting with installation or maintenance in hazardous or high-temperature environments, improving safety for human operators.

AI in Maintenance and Operation

Maintenance is an area where AI could bring particularly strong benefits. Predictive maintenance systems use data from sensors to anticipate component wear or failure, enabling service teams to act before a breakdown occurs.

AI can also be applied to continuous efficiency monitoring, automatically adjusting burner performance to maintain optimal combustion and reduce fuel consumption and emissions. Diagnostic algorithms could help detect faults such as incomplete combustion, leaks or inefficient heat transfer, supporting safer and more reliable operation.

Wider Industry Impact

Beyond individual systems, AI could support broader developments in the process heating sector. For instance, it can assist in modelling the transition from natural gas to hydrogen or hybrid fuel systems by simulating combustion performance and safety considerations.

AI-based tools could also simplify administrative tasks by automating compliance reporting — tracking emissions, efficiency data and safety checks — saving time while improving traceability.

An Opportunity for the Industry

For companies across the sector, including those with deep engineering expertise, there may be opportunities to codify specialist knowledge into AI systems, ensuring that decades of experience can inform the next generation of heating technology.

While these technologies are still evolving, the underlying principles remain the same: high-quality engineering, rigorous safety standards and sound technical judgement will continue to be essential.

Fairburn Heating Solutions will continue to monitor these developments across the industry to stay informed about emerging technologies and their potential influence on future heating system design, installation and maintenance.

Would you like some help with design, installation or maintenance of a process heating system?  Speak to us today.

A recent study by IDS‑INDATA – The Real Cost of Downtime in Manufacturing: Sector‑by‑Sector Breakdown and 2025 Forecasting – highlighted that the cost of unplanned downtime for UK and European manufacturers is likely to be over £80 billion in 2025. That’s a staggering figure and a clear call to action.  Survey data suggests that over 80% of industrial businesses experienced some unplanned downtime in the last three years, with an average duration of four hours.  In the UK on average, every company loses 49 hours of productivity every year.

Key drivers behind this crisis include:

• Ageing machinery and legacy systems
• Cyber vulnerabilities within interconnected Operational Technology (OT)
• Supply chain instability and energy price volatility
• Seasonal demand placing extra stress on equipment

These factors aren’t unique to specific sectors—they impact all manufacturing, especially in energy- and heat-intensive industries.

The IDS‑INDATA’s data shows:

• Heavy Equipment: Extended restart times and long shutdowns are estimated to cost £50–60 billion across the EU
• Automotive: A forecast 20–25 breakdowns monthly, each costing £1.6–2 million per hour—totalling £10–12 billion in 2025
• Food manufacturers: typically disruptions are shorter, but more frequent meaning total losses across the sector are still forecast to be £4-5 billion
• Pharmaceuticals: a single major incident can cost £5-£10 million

Downtime isn’t just numbers on a page – it means lost productivity and revenue; emergency repair costs; delay to key projects and in the long run, damaged reputation and client trust.  In some operations, just one hour of breakdown can cost millions of pounds in lost output, create supply chain bottlenecks and even compliance issues.

The report strongly recommends shifting towards Predictive Maintenance.  By collecting real-time data from equipment, manufacturers can anticipate issues before they happen – transforming unexpected stoppages into planned maintenance windows

At Fairburn Heating Solutions, we recommend Predictive Maintenance to all our clients, as part of our Asset Management Journey which reduces breakdowns and grows productivity.

Contact us today on 01886 358025 to discuss how we can ensure uninterrupted manufacturing success.