2023 Boiler Report: Keeping the Industry Running Hot

The boiler industry is undergoing significant changes as manufacturers navigate a rapidly evolving landscape of trends and challenges. On one hand, there is a growing emphasis on energy efficiency and digital technology, with new products and features emerging to meet these demands. On the other hand, manufacturers are contending with increasing competition, fluctuating raw material prices and supply chain issues, and evolving regulations and standards.

The boiler industry as a whole — engineers, contractors and wholesalers — is a vital component of the global economy, with a market size that exceeded $85 billion in 2022 and is projected to continue growing at more than 7.5% CAGR from 2023 to 2032, according to Global Market Insights (http://bit.ly/3FuV7JX). It’s clear that the challenges that exist are not enough to slow this industry down — in fact, we’re ramped up and ready to go the distance.  

To gain insight into the current state of the industry, we reached out to 18 industry-leading manufacturers. Aerco, Bosch, Bradford White, ECR International, HTP Boiler (Ariston USA), IBC (Rheem), Laars Heating Systems, Lochinvar, Navien, Noritz, NTI Boilers, RBI (Mestek), Rinnai, Thermal Solutions, Triangle Tube, U.S. Boiler Co., Velocity Boiler Works, and Weil-McLain shared their thoughts on the challenges and trends impacting the industry. From the push to meet the diverse needs of different market segments and to the impact of evolving regulations and standards, these manufacturers offered valuable insights into the state of the boiler industry.

Boiling Points: Regulations, Standards and Future Trends 

The U.S. boiler industry is undergoing a significant transformation as the push for electrification and decarbonization intensifies. As the U.S. moves toward renewable energy sources and lower emissions, the role of traditional boilers in buildings and homes is changing, and alternative heating technologies are becoming more attractive 

Before we dive into the trends, it’s key to understand what is pushing them forward. 

Like most industries, the boiler industry is subject to a range of regulations and standards related to safety, emissions and efficiency — which continue to evolve — and manufacturers must adapt their products and processes to comply with new requirements. 

The U.S. Department of Energy recently updated minimum efficiency standards, effective Jan. 10, 2023, for commercial packaged boilers. That’s just the latest of many regulations that have come and gone, and many more that are in the works still. 

Eric Truskoski, vice president of administration and government affairs at Bradford White, notes, “The U.S. DOE is in the middle of a rulemaking for residential (consumer) boilers, and based on the DOE’s regulatory agenda, we should see a proposed rule later this year and likely a final rule next year.”  

This isn’t news to anyone in the industry — not engineers, contractors or wholesalers, and especially not the manufacturers we spoke with. Neither is the fact that consumers are also part of the push for more efficient products. As homeowners continue to upgrade and replace existing systems in their homes, the call for environmentally friendly products with a smaller footprint also continue to grow. And it’s not just homeowners. Commercial spaces, including federal buildings, hospitals, schools, etc., require more energy efficient options, too. 

In fact, the DOE’s new building energy code requirements for federal buildings (http://bit.ly/3lmVorA), which came into effect in March 2022, aim to cut down energy use and electrify appliances and equipment in 30% of federal government-owned building spaces by 2030. These new building codes are also creating notable impetus for the substitution of conventional heating systems to meet new energy efficiency provisions and LEED certification guidelines.

So, how are manufacturers responding? It’s not a one-size-fits-all. In fact, a lot of it depends on where in the country products are being manufactured and sold. But one thing that is clear, they are all meeting the challenge head on with innovative solutions that not only meet consumer and regulatory demand, but in some cases, even exceed it. 

In fact, product manager Christopher Kyes insists, “Environmental stewardship is one of our core philosophies at Bosch. It inspires us to innovate solutions that are climate-friendly and reduce our carbon footprint. We see the market recognizing this need as well in the increased demand for high efficiency, condensing boilers.” 

Bosch isn’t the only manufacturer boasting high efficiency condensing boilers. Most of the manufacturers, including Aerco, ECR International, IBC, Navien, Triangle Tube and others highlight their products in this category.  

But coming off the heels of 2023 AHR Expo, the buzz was around decarbonization. According to the 2023 Trend Report (https://bit.ly/40im3V0) released before the expo, regulations remain a driving force toward a cleaner future, and that places an emphasis on eliminating carbon emissions. In fact, the AHRI board of directors just last year approved a decarbonization statement (http://bit.ly/3lndbyM) reiterating the association’s position in support of efforts that reduce carbon emissions while ensuring continued affordable consumer access to HVAC and water heating products and equipment that meets their needs.

One way to achieve decarbonization in the boiler industry is to switch from traditional fossil fuels such as coal and natural gas to renewable energy sources like biomass, hydrogen or electricity from renewable sources. Another way to decarbonize is to increase the use of alternative heating technologies like heat pumps, which have gained popularity in recent years. 

The White House recently announced a $250 million investment from the Inflation Reduction Act (http://bit.ly/3TDYOmB) to increase production of domestic heat pump manufacturing. These initiatives are expected to further drive the adoption of alternative heating technologies and contribute to the decarbonization of the boiler industry.

Not everyone is convinced, however, that the time is now. “It is still early days for the boiler industry with regard to heat pumps,” says Christian Zapata, product manager of hydronic solutions at Aerco. “It is true that heat pumps have gained significant interest in meeting building decarbonization goals and stringent government regulations. There are challenges, however, including (1) heat pumps require a larger footprint compared to gas solutions, and would rely on the use of thermal storage to meet peak load demand, and (2) how to maximize the benefit of the heat pump system such that it operates during times of the day when utility costs are low. That said, Aerco is looking closely at the market and evolving technologies with regard to heat pumps and other solutions that can meet customers’ space heating needs.”

Adapting Boiler Solutions to Meet Sustainable Demands of Today

To meet the sustainability demands of today, the boiler industry is turning to electrification and heat-pump technology. Let’s break it all down… 

Electrification

Electrification is a crucial step in decarbonization, as it involves the transition from fossil fuel-powered boilers to electric boilers. Electric boilers are highly efficient, emit no pollutants or greenhouse gases, and are often cheaper to install and maintain. Electrification also enables the integration of renewable energy sources, reducing the carbon footprint of commercial and industrial buildings.

However, electrification alone is not a complete solution to decarbonizing the boiler industry. The electricity used to power electric boilers must come from renewable sources for a sustainable future. Electrification also requires significant investments in infrastructure, which may not be viable for all building types.

Jim Schnorr, vice president of sales at Thermal Solutions, notes that although the push for electrification aims to increase energy efficiency, “it’s ironic that there seems to be little consideration given to the energy losses that occur during the generation and transmission of electricity.” 

Nick Lane, product manager of hydronic solutions at Aerco, agrees, noting, “Engineers and facility owners need to take a close look at all factors in boiler systems, particularly as there is a move toward electrification. Careful consideration must be given to whether the grid can satisfactorily handle the increase in electricity demand created by a switch to an electric boiler or heat pump. For projects with a strong focus on the environmental impact, it is key to consider how the electricity is produced at the power plant. Coal is an obvious example. In cases where a power plant uses natural gas to generate electricity, it is often much more energy efficient when used at the local source, such as a gas-fired boiler.”

As electrification becomes more popular however, it gives way to heat pump technology, which offers a more energy-efficient and sustainable alternative to traditional boilers. “We have seen heat pump technology and presence increase significantly over the years,” says Dave Walsh, vice president of sales at NTI-USA. “It’s clear that the current electrification push is driving that even faster.”

Heat Pump Technology 

Heat pump technology is another important solution in the boiler industry’s shift toward sustainability. And, according to the 2023 Trend Report out of AHR Expo, heat pump technology is advancing at a remarkable rate — this is especially true in regions with mild climates. 

It’s not just milder climates, however; heat pump technology continues to grow in popularity in certain parts of the country, too. Louise Prader, senior director of product management at Bradford White, notes that this is happening primarily in the residential sector — in areas where utility rebates are in place and different policies are requiring it. “We have to make sure that our electric infrastructure, manufacturer and supply chain capabilities, and installer confidence are all aligned to work toward some of the aggressive regulatory goals built around heat pump technology.” 

So, how exactly does heat pump technology work? By moving heat from one place to another, heat pumps provide an efficient and renewable way to heat and cool buildings. They can also be powered by renewable energy sources such as solar or wind, further reducing their carbon footprint. In addition to being sustainable, heat pumps are highly versatile, offering a range of options for different types of buildings and climates 

Despite their growing popularity, however, some manufacturers remain cautious to move too quickly. “We have seen this happen in the past,” says Dave Hoskyn, product management director at Navien. “When an energy code change forces the industry to adapt to new regulations, often these changes are put in place without fully addressing the challenges that new products bring.” 

He adds: “Heat pumps are a viable option in some cases, but energy supply and demand will need to be addressed. Along with the electricity required to operate, low temperature performance and maximum supply water temperatures must be looked at, especially when considering replacing boilers. HPWH technology will soon be undergoing revisions to replace current refrigerant with more greenhouse gas friendly products. Navien is exploring options with heat pumps, since we know they are here to stay. We want to be sure that if — and when — we introduce a product it will meet the needs of the market and our customers.”

Andrew Tran, senior marketing manager at Noritz, echoes that sentiment, noting that even as Noritz is committed to reducing the company’s carbon footprint by 30% by 2030, “we are still in favor of a cautious mixed approach. Heat pumps may ultimately become the primary means to obtain the goal of heating the home with zero carbon emissions, however Noritz is still pursuing a mix of technologies to account for various infrastructure, technological, environmental and comfort factors.” Noritz believes this mixed approach is ultimately the best way forward versus focusing on a single solution.   

Jim Schnorr, vice president of sales at Thermal Solutions, also agrees in that there is so much more to consider outside just the benefits of decarbonization. “This is hitting all parts of legacy hydronic systems. This is coming despite so many questions around grids, supply, cost to run, costs of equipment, the size of equipment, and true impact on the environment. Change brings opportunity — and this change needs major subsidies to drive it, and supplying electric past what we can today remains a big hurdle.” 

While most all the manufacturers we spoke with see heat pump technology making its presence known — and weaving its way into the manufacturing plants — some were already discussing current or future plans to introduce new products that will meet consumer demand.  

“In addition to offering some of the most reliable boilers in the world, we also provide highly energy-efficient water-source, geothermal and air-source heat pump systems,” says Bosch’s Kyes. 

Prader of Bradford White adds, “We are actively engaged in the heat pump water heating space and continue to invest in new technologies and products, such as Bradford White’s AeroTherm HPWH with BW Connect, to support the current and future needs of our customers.” 

Bob Shea, executive director of ECR International, notes, “ECR provides our valued customers two complete heat pumps lines — the Maximum Heating and Advantage Series. We’ve elected to provide two offerings because we recognize that applications vary and not all projects will require the same features and benefits giving our customers a choice that best suits their needs. 

“There is a worldwide movement toward electrification, and we intend to be a part of it,” says Doug Dodds, vice president of sales and marketing at IBC. “We are presently developing an air-to-water heat pump and a proprietary control system that will control the heating, cooling, domestic hot water and a gas or electric boiler as part of a hybrid system.”

“Heat pump technology will play an important role in the future of space and water heating and Laars is developing heat pump technology to meet those future needs,” says Chuck O’Donnell, director of marketing. He does add, however, “gas-fired boilers and water heaters will continue to play a critical role for years to come as the electrical supply infrastructure is built out to support North America’s electrification goals. 

Jennifer Russell, segment development manager for decarbonization at Lochinvar, says: “With the continued growth of the heat pump water heater market, Lochinvar has ensured that we are well-poised to meet the increasing demand head on. We offer both air source and water source commercial heat pump water heaters as well as residential heat pumps water heaters. Since heat pump water heaters require storage tanks, Lochinvar also offers our patent-pending Thermal-Stor Heat Pump water heater storage tank, which features a unique baffle to keep hot water at the ready with its continual stratification. Lochinvar also unveiled an exciting new product at this year’s AHR Expo — the Veritus air source commercial heat pump water heater.”

“Mestek, Inc., our parent company, has us well positioned for a potential shift in the marketplace,” notes Matt Kleszczynski, director of marketing at RBI. “We have been providing heat pumps residentially for more than 12 years under the SpacePak brand of products. Commercially, we recently introduced an air-to-water heat pump under the RBI and Advanced Thermal Hydronics brands to fully complement our existing hydronic boiler and water heater segments. We also recently acquired Transom, a specialty manufacturer of both air-source and water-source commercial heat pumps designed to efficiently generate water temperatures as high as 140 degrees and 180 degrees from outside air temperatures as low as -20 degrees for both space and domestic water heating applications. Transom also manufactures a one-of-a-kind CO₂ heat pump water heater, the first commercial unit to be designed and manufactured in North America.” 

“The recent developments in heat pumps indicate that customers are looking for more efficient solutions that can eventually lead to lower carbon emissions and have less impact on the environment,” says John Kopf, senior product manager of innovation at Rinnai. “To that extent, Rinnai has been interested in developing these technologies while expanding its existing product portfolio. 

Even with all this buzz around electrification and heat pump technology, high efficiency condensing boilers aren’t going anywhere, anytime soon. As the industry continues to prioritize sustainability and reducing carbon emissions, the use of high efficiency condensing boilers will undoubtedly continue to be a major player. By capturing and reusing the heat that is typically lost through flue gases, condensing boilers can achieve impressive levels of efficiency while reducing emissions. 

As manufacturers continue to innovate and bring new technologies to market, the collective impact of these efforts will make a significant difference.

Dave DeVries, director of product management for Weil-McLain, states, “We have a broader view toward the technology challenges regarding decarbonization. This view recognizes that it will likely take all available technologies to solve our climate problem, including renewable electrification, renewable fuels, carbon capture, reduced demand from building efficiency improvements and upgrades to higher efficiency appliances. We are always exploring and evaluating new technologies and will bring them to market when they are technically and economically feasible for hydronic applications in our markets.”  

The boiler industry’s efforts to meet today’s sustainable demands involve various technologies, including electric boilers, heat-pump systems and high efficiency condensing boilers. These solutions are paving the way for a more sustainable and low-carbon future by reducing carbon emissions, improving energy efficiency and utilizing renewable energy sources.

We asked the manufacturers to tell us what steps they have taken to reduce the environmental impact of their boilers. Here’s what they had to say: 

Aerco has been ahead of the curve as our condensing hot water boilers — such as the Aerco Benchmark and Benchmark Platinum families — already meet the updated minimum efficiency standards set by the DOE for commercial packaged boilers.

—Nick Lane, Product Manager, Hydronic Solutions, Aerco

We have ensured that our heating solutions meet the 95% AFUE standard for Energy Star. Another critical way to reduce environmental impact is to optimize boiler performance. The control system we have designed for Greenstar is a great example of this. Using the Indoor Reset, the boiler can modulate its output based on the exact needs of the house — it can calculate heat loss as well as how long it will take to heat the space. This enables the unit to run more efficiently and conserve energy. To help with water quality issues, we have developed the Bosch Protection Pack, which protects the boiler and other parts in the heating system against the damaging effects of black iron oxide sludge and non-magnetic debris.

—Christopher Kyes, Product Manager, Bosch Thermotechnology

All the boilers that we manufacture and sell meet the most current efficiency standards and regulations and we are working aggressively to ensure we have products for our customers that meet any boiler regulations that are on the horizon.

—Eric Truskoski, VP, Administration and Government Affairs, Bradford White 

ECR offers products at different efficiency levels, intended to meet the needs of our customers based upon the specific requirements of the application. The assumption that the highest levels of efficiency can be installed in every application is simply not the case. We offer customer choices to allow them to make the appropriate decisions based upon their specific needs. ECR is developing bio-fuel products as well as our next generation of residential condensing boilers, all of which are intended to offer the highest levels of efficiency while reducing emissions.

—Joe Langlois, Engineering and Marketing Director, ECR International 

We are, and always have been, focused on the highest possible efficiency and lowest emissions in our HTP Boilers.

—Joshua Goncalves, Product Marketing Manager, Ariston/HTP Boiler 

For more than 25 years, IBC has been a leader in high efficiency condensing technology and product innovation. With our bold approach to product and process improvements we aim to dramatically cut our impact on the environment, while empowering both our customers and employees to work and live sustainably. It’s all a part of our bold vision for the future and equally bold commitment to designing for zero waste.

—Doug Dodds, Vice President, Sales & Marketing, IBC

Laars offers a wide range of space and water heating solutions that meet or exceed all mandated energy efficiency standards while retaining the features and benefits that are of value to our customers.

—Chuck O’Donnell, Director of Marketing, Laars Heating Systems Co 

Lochinvar’s gas-fired boilers have some of the best thermal efficiencies in the industry, so much so that when the DOE announced new regulations requiring boilers to have at least 84% AFUE, only four Lochinvar models were affected. With our expansive boiler offering, Lochinvar has a multitude of options that meet and exceed this new standard. In addition to efficient operation, we’ve put combustion under the magnifying glass and focused on the O₂ sensor of the CREST with Hellcat Combustion Technology. We’ve designed the controls to be smarter and take weather shifts and barometric pressure into account to provide top-of-the-line performance. We’re always looking to innovate and take strides to meet any requirement for any application. We have plans to make additional product introductions in 2023 and beyond that exhibit our dedication to environmental excellence.

—Jennifer Russell, Segment Development for Decarbonization, Lochinvar

All the boilers and combi boilers we produce — and sell — are condensing, and rated at 95% AFUE, so they all meet or exceed efficiency standards in the market. All the boilers can load match with a high turndown ratio and outdoor reset, and the option to operate off supply or return temperatures gives them the ability to maintain peak efficiency. Built-in combustion controls constantly adjust to maintain the air-to-gas ratio on the burner, reducing the potential for higher CO₂ emissions. Navien is also exploring ways to minimize packaging and shipping material that end up in the waste stream. We are working to ensure our products can ship to our customers without damage, while at the same time minimizing packing material.

—Dave Hoskyn, Product Management Director, Navien

Noritz has continued to develop and launch products that meet and exceed the minimum energy efficiency standards and continue to place significant emphasis on R&D to develop future products that can contribute to a carbon neutral target.

—Andrew Tran, Senior Marketing Manager, Noritz

We are constantly evaluating both our legacy and new product developments to stay ahead of the ever-changing landscape of energy efficiency and the overall reduction of the carbon footprint. Any development project — whether continuous or new product development — has energy efficiency and DOE regulations at the forefront. All the projects are a direct result of current standards and more importantly the anticipation of future changes, keeping our products performing in the most efficient, environmentally friendly way possible.

—Matt Kleszczynski, Director of Marketing, RBI 

All recently launched Rinnai products greatly exceed current DOE requirements and address future efficiency increases. Rinnai has tested and approved its boilers and tankless water heaters for use of up to 30% of hydrogen mix with natural gas. There are multiple test sites in North America and around the world where Rinnai’s hydrogen-fueled products are in use and being tested. Rinnai’s latest development in a 100% hydrogen-powered water heater proves its commitment to reducing global warming, carbon neutrality and protecting the environment.

—John Kopf, Senior Product Manager, Innovation, Rinnai

The testing to meet DOE requirements has increased efficiency levels across the board at Thermal Solutions.

—Jim Schnorr, Vice President of Sales, Thermal Solutions

All the Triangle Tube boilers are modulating condensing gas boilers that achieve 95% AFUE on the residential sizes and a 95% thermal efficiency on the commercial sizes. These are some of the highest levels of efficiency achievable with the current technology. Our focus is always on improving product efficiency while not sacrificing reliability.

—Josh Garrett, Director of Engineering, Triangle Tube

Reducing emissions while saving homeowners money with high efficiency products is a high priority. We continue to invest time and resources to comply with current and future energy efficiency standards. We are constantly investing in research and development of products that serve a greener future. One of those products is a new electric boiler, which was recently introduced at AHR Expo. This product was designed and manufactured completely in-house and represents the first in a series of new electric products offered by U.S. Boiler.

—David Hansen, Residential Product Marketing Manager, U.S. Boiler Co. 

All product offerings meet the current residential and commercial boiler energy efficiency standards. We are also aware of the demand within the marketplace for products that are greener and with that in mind, we will be introducing an electric boiler later in 2023.

—Lee Ensminger, National Sales Manager, Velocity Boiler Works

As the shift toward high-efficiency products continues and boiler thermal efficiencies remain a key design element, we are constantly looking for ways to reduce energy consumption while achieving environmental sustainability. To that end, we recently announced the availability of our 2023 DOE-compliant commercial cast iron product portfolio with enhanced boiler efficiencies. The upgraded designs of our LGB Steam/Water Series 3 and 88 Water Series 3 boiler product lines include exciting new features that go beyond just regulatory compliance. The LGB family meets the DOE regulation 431.87 requirements with enhanced thermal efficiencies up to 84% while the 88 product line sports thermal efficiencies up to 87%. Increasing the efficiencies of these boilers results in lower fuel consumption and operating costs while still providing reliable and trouble-free operation for property owners and facility managers. Similarly, our ECO Tec Series 2 is among the most energy efficient residential boilers on the market thanks to its 95% AFUE rating, while our new SVF units feature industry-leading thermal efficiencies up to 98%.

—Dave DeVries, Director of Product Management, Weil-McLain 

Different Market Segments, Manufacturing Processes, and Customer Training and Education 

To fully understand the state of the boiler market today, it is important to consider the people involved, the processes utilized, and the different market segments that exist. From residential to commercial to industrial, each sector presents unique opportunities and obstacles that must be navigated by manufacturers, engineers and installers. 

In this section, we will examine how different people, processes and market segments are shaping the boiler industry’s evolution. 

Appealing to Different Market Segments 

Boiler manufacturers have more than just standards and regulations to consider, they need to also think about consumer demands — whether it be residential, commercial or industrial — around ease of use and installation, size and functionality, as well as smart features. It is no longer enough to just produce a high-quality product; it matters more than ever to put innovation at the forefront of everything they do.  

Each of the market segments within the boiler industry has distinct needs and requirements, which means that manufacturers must be able to offer a range of boiler models that cater to each market segment’s needs and wants.  

For instance, residential customers might need smaller and more compact boilers that are energy-efficient and affordable. The residential segment is also seeing a shift toward combi boilers, which offer both heating and hot water. Bosch’s Kyes points to their own market research, noting, “The annual compound growth rate for combi boilers was +24.3% between 2015-2020.”  

IBC’s Dodds adds, “Traditionally a manufacturer of residential high efficiency condensing boilers, in recent years we have introduced combi and tankless water heater models and we are just about to introduce our first electric product line, the EBX High Efficiency Modulating Electric Boiler.” 

Weil-McLain’s ECO Tec combi boilers were developed as a direct result of a need to design products for confined spaces in retrofits and new buildings where space is at a premium. “The ECO Tec combines the warmth of high-efficiency space heating with the convenience of on-demand domestic hot water in a compact, space-saving, easy-to-install package,” DeVries says. 

Jeff Vallett II, segment development manager for hydronics at Lochinvar, notes that they continue to put development dollars toward all categories of their business and offer several solutions to support decarbonization and greenhouse gas reduction efforts. “On the residential side, Lochinvar has a great boiler range with units to fit almost any application. All units have well-managed footprints as well as easy-to-use setup and troubleshooting tools. With even more options coming soon, Lochinvar offers industry-leading gas and electric space and water heating solutions.”   

Although size, efficiency and functionality are major factors for homeowners — equally important is how well the boiler integrates with a smart home. “At Bradford White we continue to approach products from an applications perspective where we consider not only our products but how they integrate into the systems that they serve,” says Mark Avron, national sales manager of specialty products.  

Rinnai’s Kopf suggests, “Residential customers expect new HVACR products to have smarter controls and be able to integrate with their other smart appliances throughout the home. A good example would be homeowners controlling their heating and cooling equipment using smart thermostats either via mobile app or voice through Amazon Alexa or Google Home.” He adds, “Homeowners are also interested in receiving early warnings of leaks and equipment in need of preventative maintenance.” Rinnai will be launching a new mobile app that will address the needs of both, homeowners and installing contractors. 

It’s important to note that installers play a critical role in the homeowner’s buying journey. “Across the market, technicians naturally want to reduce the time needed for installation,” says Bosch’s Kyes. “We have been hard at work on improving our controls to make them simple, straightforward and easy to operate. The Singular Boiler is a great example.”  

Bradford White’s Avron agrees, noting “direct feedback from our customers tells us that time is one of their most valuable resources. With labor being at a premium in our industry today, it is even more important that we develop products that install quickly and easily.”  

Chad Marzitelli of Triangle Tube also agrees, noting, “We are constantly improving our products to meet the needs of our customers. And our latest boiler, the Instinct Floor Standing model comes with Tsync Wi-Fi connectivity built in. This innovation allows contractors to access boiler information and troubleshoot numerous issues remotely.” 

For commercial and industrial customers, larger and more powerful boilers are often necessary to handle high volumes of hot water or steam. However, they also seek products that can reduce operating costs and downtime.  

To help installers save time and space, modular designs have become a popular choice. “The Bosch SSB paired with the SSB Low Loss Header provides the whole primary loop for a boiler system. The Low Loss header combines high performance air and dirt removal with hydraulic separation as well as to make piping and installation of the primary loop easier,” Kyes says. “The SSB modular design allows technicians to connect the boilers right up to one another to save space. Four SSB boilers can be connected to allow up to 4 million BTU of input.” 

Preventative maintenance and remote access to equipment can also prevent costly replacements and downtime. “And for commercial customers,” Kopf says, “avoiding downtime and costly replacements is the key. Since commercial systems are much larger than residential ones, minimizing their operating costs is also important. Rinnai has been working on adding new commercial boiler sizes featuring industry-leading efficiencies. These new boilers will have 97% thermal efficiency, include Wi-Fi and MBS connectivity, as well as intuitive controls with 7-inch color display.” 

Just like on the residential side, the ability to manage boiler-to-boiler communication within the overall building automation system is critical in commercial applications as well. “This allows for lead-lag boiler operation for run time level-setting and overall fuel consumption efficiency,” DeVries says. “Hybrid boiler applications have become more popular as the industry recognizes their design. For example, a non-condensing boiler can be used for lead operation in the core heating season months while a condensing boiler design can be used for lead operation in the heating season shoulder months. These can be especially effective in higher temperature replacement applications. Weil-McLain has the commercial boilers and controls to maximize system efficiency while seamlessly integrating into communication networks.” 

Whether it is for residential, commercial or industrial applications, manufacturers must continue to develop products that are easy to install, reducing installation time and labor costs — but that are also environmentally friendly and efficient, particularly as the push for electrification continues.  

Maintaining Production and Manufacturing Processes During Uncertainty  

One of the biggest drivers of change in the boiler industry’s daily operations has been the shortage of a skilled workforce, making it difficult for companies to recruit and retain talented employees, which can in turn impact the quality and efficiency of their operations. 

This challenge, alongside the call to run more environmentally friendly operations, has led to a shift toward more advanced manufacturing technologies, such as automation and robotics, that can help companies reduce their energy consumption and improve their environmental footprint — and help with labor shortage.  

Peter Kattula, senior vice president and general manager of Bradford White, notes, “We are investing in our manufacturing processes and effectiveness to meet the evolving needs of our customers as well as regulatory changes. Continuous improvement and innovation are foundational to our culture, and we are always working on improving our quality and operational efficiencies. As staffing continues to be a challenge, we are leveraging automated technologies in equipment, and offering skill upgrade opportunities to our team members so we can continue to manufacture our ‘Built to be the Best’ products.” 

Although automation and robotics has its advantages, these technologies do require significant investment and retraining of the workforce, which can be difficult when times are already strained. 

Laars’ O’Donnell says: “We have progressed overall manufacturing effectiveness considering staffing challenges by leveraging advancements in equipment, such as robotics and automated production capabilities, and in people by cross training manufacturing team members to create a more flexible workforce. These changes have produced a much more efficient and nimble operation.” 

Another major challenge facing the boiler industry is the ongoing effects stemming from the pandemic, which have resulted in disruptions to global supply chains. This has led to shortages of critical materials and components, which has caused project delays and uncertainty in project completion. To address this challenge, manufacturers are exploring new ways to reduce their dependence on traditional supply chains and increase their resilience to future disruptions.  

“Fortunately, Aerco manufactures most of its boilers — including our heat exchangers — in our Blauvelt, N.Y. and Ft. Worth, Texas facilities, so we were already committed to domestic manufacturing to better meet manufacture and delivery times,” Lanes says. “One of the changes that we implemented that will remain is that we have a more robust supply chain with additional suppliers. This aids our ability to maintain delivery schedules.”   

Lochinvar’s Vallett stresses the importance of communication: “Everyone in the industry faced challenges with the supply chain in 2022 and we took this as a learning opportunity to further improve our production and manufacturing processes. We learned that it’s critically important for all the cards to be on the table to ensure a smooth process. Through our representative relationships, we’ve put measures in place to optimize lead times, meet delivery dates and ensure availability. We’ve also evaluated our order entry process as it relates to production planning and made great improvements that give our employees, reps and end users even more confidence in our brand.”  

In the 2023 Trends Report released before AHR Expo, AHRI noted: “AHRI members and staff have spent considerable time and resources seeking ways to ameliorate the [supply chain] issue, including working with the Department of Commerce, the International Trade Administration, the Department of State, and other entities on potential solutions. In the same report, HARDI noted that “because of supply chain delays, distributors need to keep more inventory. Not only are there additional financial costs associated with carrying extra inventory, but operational efficiency is compromised when trying to function around it.” 

Like all manufacturers, Navien has its share of supply chain and logistical issues. However, Hoskyn says: “Since we produce almost all the components in our products — from the heat exchanger to the control boards — we have been able to control many of the issues and continue to produce and supply products. The availability of raw materials, along with the cost of those, need to be closely reviewed to ensure production levels, since the global markets can quickly change. Logistical issues will also need to be closely monitored as truck, rail and overseas shipping always seem to have a new issue come up each week.”  

Joe Langlois, engineering and marketing director at ECR International, agrees about the issues with logistics and procurement. “Parts availability, especially electronics, has and will continue to be an issue. To address optimizing manufacturing, ECR has a robotics project that will be completed in 2023 to increase productivity.” 

To succeed in the new normal of manufacturing and production processes in the boiler industry, manufacturers need to be agile, adaptable and innovative. They need to be willing to embrace new technologies and processes, invest in their workforce and collaborate with suppliers and other stakeholders to build a more resilient and sustainable supply chain.  

This requires a long-term strategic vision, a commitment to continuous improvement and a willingness to take risks and embrace change. Ultimately, those companies that can adapt and thrive in this changing landscape will be the ones that emerge as leaders in the industry. 

“The recent supply chain and manufacturing struggles have made everyone take a second look at manufacturing partners and sources and processes,” Noritz’ Tran says. “Those manufacturers that were most agile and flexible were able to ride the wave better than those who weren’t, so I think everyone has built-in contingency plans now that the weaknesses have been exposed.”  

“The last three years affected all manufacturers with delays in our supply chain and it did influence the pace of production of some of our manufacturing lines at times,” DeVries says. “An array of challenges stressed the system, not only supply chain related, but also personnel and training related items. Despite this, Weil-McLain has been able to quickly adapt and become stronger and nimbler as an organization. Our bench depth of approved alternative suppliers and materials has deepened. Our inventory management strategy has been modified and optimized to match the new environment. Our continued focus on harmonizing the efforts of our purchasing, HR, production, product management and engineering teams has helped to minimize any such disruptions while spurring innovation. We continue to do everything we can to meet demand and expect continuing improvement in supply chain factors throughout 2023.”  

While supply chain issues have improved from the start of the pandemic, we are not still too normal. Or perhaps, this is just the new normal. In the 2023 Trends Report released before AHR Expo, HARDI stated that data suggests that the supply chain is in better health than it was a year ago. “There is progress, but gaps persist. High distributor inventories coupled with easing demand will relieve pressure on the supply chain, allowing reliability to continue to improve.” 

Some manufacturers are taking steps to create their own new normal around all this uncertainty. 

To improve the delivery of its products and serve customers better, Rinnai invested in the opening of its new headquarters in Peachtree City, Ga., along with the introduction of a product strategy designed to bring new products to market. In addition to the new HQ, the new manufacturing and distribution center was opened in 2022 in Griffin, Ga., to bring Rinnai closer to its customers.  

“Fortunately, for the most part our teams did a tremendous job navigating supply chain issues and workforce concerns and our lead times stayed relative to our previous business climate across most of our boiler products,” Kleszczynski says. “RBI dealt with concerns as they surfaced and communicated openly with our customer base insuring transparency across the board. We, like others, had areas of concern but have taken the necessary steps to remedy them and establish new protocols to help prevent future occurrences. Some issues were flat out unavoidable, but, as stated previously, communication goes a long way into making difficult situations more tolerable.”   

IBC’s Dodds notes that they’re focused on innovating with intent engineering solutions with lifetime sustainability in mind, from material selection to smart features to responsible recycling. “We’re striving for operational excellence, working smarter and more sustainably to consume fewer resources, generate less waste and ensure simpler, safer processes,” he says. We’re also hiring and inspiring our teams to be next-generation thinkers and responsible stewards of our industry, the greater community and the environment.”  

“With some major investments from our parent company, Ariston Group, we have expanded our production capabilities,” Walsh states. “There were some growing pains but the manufacturing resources that we have access to with Ariston has allowed us to utilize a more structured and rigorous methodology to strive for operational excellence and apply methods and standards rigorously through the involvement of everyone on the team. Key benefits are performance increases in terms of ergonomics, safety, environment, energy, quality, cost, inventory, flexibility and service levels.”  

A critical part of the manufacturing puzzle — regardless of market segment or production processes — is ensuring that customers (engineers, contractors and distributors) are fully trained on designing for, installing and servicing the boilers.  

Customer Training and Education 

All the manufacturers we spoke with have developed various training and education programs to improve safety, performance and perception of their products. We asked them to discuss the different kinds of training and education programs they offer industry wide. Here’s what they had to say:  

“Aerco uses a ‘blended learning’ approach to reach customers in multiple formats conveniently. From our world-class Learning Management System to our hands-on Learning Centers, we had more than 3,000 course completions in 2022. We have web-based boiler training courses ranging from basic to advanced, virtual courses, webinars, videos and hands-on training. Technicians can visit one of our Learning Centers and become certified as an AercoTrained Technician and can eventually become an Aerco Master Technician.

—Christin Zapata, Product Manager, Hydronic Solutions, Aerco 

“We offer Bosch Product Trainings across all product lines through our eAcademy platform that are designed for contractors, sales representatives and engineers. Create an eAcademy account at www.training.boschprohvac.us to see what trainings are available in your area.”

—Christopher Kyes, Product Manager, Bosch Thermotechnology 

“Bradford White is committed to training the professional contractor. We offer several training options at our International Technical Excellence Center (iTEC) in Middleville, Michigan. In-person field training is also available during our Bradford White trailer days in addition to our online For the Pro Training Academy. For the Pro Training Academy combines our existing in-person training programs with a new self-paced eLearning option for our valued Bradford White contractor customers, creating even more convenience and access in today’s fast-moving world to help them be successful.”

—Carl Pinto, Senior Director, Marketing Communications, Bradford White 

“ECR provides state-of-the-art training at both our Dunkirk and Utica facilities with fully operational equipment stations for true hands-on training. We recognize the importance of quality training and can bring it directly to the customer. Our team of Field Support Representatives has mobile Live-Fire demonstration and training units and travel through our service territories providing quality hands-on training to our valued customers. In addition, we offer a library of training and troubleshooting videos and vignettes on our dealer portals to support our customers when they are in the field.”

—Bob Shea, Executive Director, ECR International 

“For 2023 Ariston has added two NATE certified classes to our roster: Hydronics 101 and Condensing Fine tuning. These classes will get the attendees three CEU credits each.”

—Joshua Goncalves, Product Marketing Manager, Ariston/HTP Boiler 

“We offer comprehensive training on all things hydronic and are putting the finishing touches on our brand new, 6,000-square-foot, state-of-the-art Innovative Learning Center in Lawnside, N.J. The learning center features a 2,500-square-foot “hot room” with live-fired equipment for a hands-on learning experience. The grand opening is set for July 2023. This is in addition to our existing training center in Sheboygan, Wis.”

—Doug Dodds, vice president of Sales & Marketing, IBC 

“Laars holds many training sessions for contractors and distributors at our Laars Customer Center located at our headquarters in Rochester, N.H. The Laars Customer Center offers training on live-fired equipment allowing contractors a true hands-on educational experience. There are also many online technical training courses offered via our Laars Academy series that can be taken when convenient to our customers.”

—Chuck O’Donnell, Director of Marketing, Laars Heating Systems Co. 

“Lochinvar’s well-established Lochinvar University has geared up for 2023 with our annual offering of courses for almost every product line. To accompany the in-person offerings, we also have LochinvarU, which provides customers with the tools and resources they need to be successful. We recently expanded our LochinvarU offerings with the addition of Hellcat content and we plan to develop even more content throughout 2023. As demand arises, our Technical Training group also offers field-training classes on a variety of topics — ensuring we cover all necessary bases for training and education.”

—Jeff Vallett II, Segment Development Manager for Hydronics, Lochinvar 

“Navien has always had a focus on training, since we understand the benefit that it has not only to the contractor, but also for us. Product familiarity reduces installation time and issues and improves the service aspect of all our products. We provide training through our manufacturing reps, our sales team, and we also have territory trainers throughout the U.S. and Canada. In addition, we have our three training academies in Irvine, Calif., Moorestown, N.J., and Woodbridge, Ontario. We have training videos and other online resources, but we find our industry is still very dominated by face-to-face and hands-on training. We try and provide the options that meet the needs of the customer.”

—Dave Hoskyn, Product Management Director, Navien 

“We offer both on-site training as well as online training. We are currently changing our online training to be more video heavy and ‘bite-sized’ to help cater to busy schedules and make the information more digestible.”

—Andrew Tran, Sr. Marketing Manager, Noritz 

“NTI has always held training and technical support as one of the pillars of what we do. We conduct factory training throughout the country from New York to Alaska. Soon we will be putting our seventh and eighth live-fire demo vans on the road. These vans allow us to take hands-on training right to the contractor. When we train in more of a classroom setting, we always interject a hands-on component to the classroom theory part. We are a tactile industry that learns best by putting our eyes and hands on the equipment.”

—Dave Walsh, Vice President of Sales, NTI-USA 

“Training has been a staple of marketing and educational initiatives for well over a decade through The Reed Institute and our director of training. The Reed Institute provides a combination of application-specific seminars tailored to the engineers of the world along with technician-specific seminars tailored to all capacities of the technician from installation and start-up to service. Several of our application-specific courses are accredited and offer professional development hours to attending engineers, which can be applied towards their annual certification requirements. We also offer fully customized training initiatives geared towards specific requests from our customer base. Trainings are held regionally throughout the U.S., Canada and Puerto Rico as well as at The Reed Institute facilities in Westfield, Mass., and Mississauga, Ontario. All Reed Institute trainings are provided at no cost to attendees and are coordinated through our manufacturer’s representative network across North America. We also provide online webinar-based trainings and a myriad of short video tutorials covering all our product offerings.”

—Matt Kleszczynski, Director of Marketing, RBI   

“Rinnai has been at the forefront of innovation and developed many educational programs for contractors and wholesalers to help them get up to speed on the new products. The educational sessions are offered through the Rinnai Training Center, either in person at the factory or in the field. There are also many online training opportunities including webinars that can be viewed remotely.”

—John Kopf, Senior Product Manager of Innovation, Rinnai 

“Triangle Tube offers both contractor and distributor training on all its products. For distributors we offer basic product training for both counter and inside sales personnel. For contractors we offer multiple levels of product training from a two-hour product introduction to an eight-hour complete product training. We will be offering basic hydronics application courses this year as well.”

—Josh Garrett, Director of Engineering, Triangle Tube 

“With so many hydronic products available to residential customers, we thought that it would be helpful to offer something that would compare competitive products to those that U.S. Boiler manufactures. The result was the launch of an online comparison tool, www.boilercrossreference.com. It offers an honest and straightforward assessment and comparison of more than 1,500 residential boiler models. This site was originally intended for use by distributors, but the information is also very helpful for contractors as well.”

—David Hansen, Residential Product Marketing Manager, U.S. Boiler Co. 

“In person training whether it be at our live-fire training room or on-site at a distributor’s or contractor’s location is still a primary focus for us. This allows us to interact in a more direct and personal way with those in attendance. These trainings range from product specific training to more generalized knowledge such as system troubleshooting.”

—Lee Ensminger, National Sales Manager, Velocity Boiler Works 

“We continuously work with channel partners, providing education to improve technical skills needed to install and maintain equipment, as well as application knowledge to ensure the correct type of product selection. On the product side, we are constantly developing equipment that utilizes ‘plug-and-play’ technology for easier installation and troubleshooting and increased field productivity and reliability. Our technical training team also hosts regular educational sessions that cover both our high efficiency residential and commercial boilers. The livestreamed Weil-McLain Knowledge Builder Sessions cover a broad range of topics from maintenance and troubleshooting to technological features and benefits, standard controls and installation tips. Contractors, engineers and facility managers alike can select a specific course at www.weil-mclain.com/training for in-depth product training and to gain insider tips for keeping Weil-McLain boilers running at peak operational efficiency. Our in-person distributor and contractor visits, as well as our popular School of Better Heating training sessions, cover these same topics. Our ProTools App also acts as an additional tool and resource for contractors and other heating professionals as it helps enhance their hydronic expertise by putting a variety of Weil-McLain boiler product information at their fingertips. From reviewing fault codes for troubleshooting and accessing how-to videos to viewing product manuals and schematics and quickly finding parts, the app has become a one-stop resource for boiler installation and maintenance.”

—Dave DeVries, Director of Product Management, Weil-McLain

The Push to Keep the Industry Running Hot  

The boiler industry continues to thrive and adapt in today’s dynamic market. Despite the challenges faced, the industry remains committed to delivering high-quality products and services to customers in every market segment.  

As we move forward, we can expect to see continued innovation and advancements in boiler technology, which will only strengthen the industry’s position. A big thank you to all the manufacturers who shared their insights and expertise with us for this report. Your dedication and hard work are truly appreciated, and we look forward to seeing the exciting developments yet to come. 

Editor’s Note: Visit www.phcppros.com to get more insights with bonus questions asked of the manufacturers interviewed for this year’s boiler report.

We asked manufacturers to share the latest developments in their product lines and here’s what they had to say:  

Aerco has developed an outdoor enclosure for its Benchmark and Benchmark Platinum series that allows the high efficiency condensing boilers to be installed outdoors. The enclosure is made from corrosion-resistant 5052 aluminum alloy and zinc-coated steel construction to safely protect the boilers from the elements, creating an added level of design flexibility and indoor space savings. We have also upgraded our Modulex EXT boilers with the award-winning Ufly controller, which features a color touchscreen and intuitive menu that enables users to save setup time and lower startup costs, while also making it quicker and easier to operate the boilers. With the upgraded controller, users can restrict boiler control access via password protection and rename heating circuits, which is advantageous for jobsite zone identification.

—Christin Zapata and Nick Lane, Product Managers, Hydronic Solutions, Aerco 

Bosch has focused largely on condensing boilers in the latest additions to our product line. Our goal is to develop comfort solutions that are highly efficient and easy to install. Our Bosch Singular Combi Boiler meets two household needs — heating and hot water — with the same unit. In addition to providing efficient, dependable home heating, Singular can also provide up to 5.2 GPM of domestic hot water production. This system is compact and weighs under 80 pounds, which makes installation very easy. The Bosch Greenstar Boiler is highly efficient, reliable and a great choice for providing comfortable heating and domestic hot water. It is available in both heating-only and combi versions. Because Greenstar operates so quietly, this boiler is also a great option for spaces that function as a room. Both Singular and Greenstar achieve 95% AFUE efficiency.

—Christopher Kyes, Product Manager, Bosch Thermotechnology 

Bradford White will be extending the product range of our highly successful Brute FT series boiler up to 399 MBH to provide our customers with a solution for large residential and light commercial applications. The extended FT range is suitable for both wall or floor mounting and is built on the same fire-tube heat exchanger, combustion technology and control platforms as our current Brute FT wall- and floor-mounted residential boilers.

—Mark Avron, National Sales Manager, Specialty Products 

ECR International has expanded our venting options to include PVC venting to support the contractor with ease of replacement as the condensing industry continues to mature and first-generation condensing boilers are reaching their expected life cycle. In addition, we provide a primary manifold with our condensing platform that attaches directly to the boiler piping connections to save the contractor time and money.

—Bob Shea, Executive Director, ECR International 

IBC has just introduced the new and improved Superflow product line of boilers and combis. Featuring the latest in condensing technology, they now feature a unique wireless cascade system which allows up to eight units to operate together for large projects and is the first of its kind in North America. 

—Doug Dodds, VP Sales & Marketing, IBC 

Laars Heating Systems Co.’s newly redesigned Laars NeoTherm XTR boiler and volume water heater will be released later in 2023 in sizes from 399 to 1500 MBH. The new NeoTherm XTR will feature 95+ percent thermal efficiency, a 10:1 turndown firing rate, the intuitive-to-use LaarsLinc control system, low pressure drop, top piping and gas connections, along with many more contractor friendly features. Also being released in 2023 is an extension of the Laars FT Series wall-hung boilers with 95+ percent thermal efficiency in 301 and 399 MBH sizes. These new FT Series boilers include features such as top and bottom water and gas piping connections for ease of installation, up to 10:1 turndown to better match building load profiles, multi-temperature zone control, and DHW control with smart priority where both space heating and indirect domestic water heating can occur at the same time.

—Chuck O’Donnell, Director of Marketing, Laars Heating Systems Co. 

Lochinvar’s newest boiler launch is the Noble floor mount combi boiler, which is also sold in Canada under the name Epic. These models are available in the same BTU/hour inputs as the popular wall-mount Noble units — ranging from 115,000 to 199,000. The Noble floor mount was introduced to allow for even further installation flexibility, especially in installations where there is more floor space readily available than wall space. This version offers the same easy setup and servicing features that contractors have come to expect from Lochinvar’s Noble boilers.

—Jeff Vallett II, Segment Development Manager for Hydronics, Lochinvar 

Navien’s NHB boilers will be updated in 2023 to add the same control features we have on the rest of the lineup. They will maintain the same capacities (50, 80, 100, and 150k BTU) with a high turndown ratio (up to 15:1), with the addition of the easy to set up and use multi-line control interface, along with built in zone control for up to three zones of pumps or zone valves. The controls will reduce some installation costs for time and materials and provide unified controls across all the residential lineups. Our commercial boiler products will see a couple additions, with the NVW Volume Water boiler coming out with storage tank options to add to the system. The NVW has similar features to our current NFB-C fire tube commercial boilers, with high turn down ratios and easy to use touch panel control. The NFB-C boiler lineup will also see an expansion of the capacities that are available. Currently offered in 301k BTU and 399k BTU, we will introduce additional sizes up to 1 million BTU input. In addition to adding or updating boilers, Navien is expanding the water treatment products we currently offer. With the greater need and awareness of water quality, and the negative affect that poor water quality in a combi or boiler can have on the performance and lifespan of the products, having products to address issues will continue to be an important part of our product offering.

—Dave Hoskyn, Product Management Director, Navien 

NTI-USA has several product updates. First, we continue to expand our onboard Wi-Fi, NTInet, as standard equipment for many of our products. NTInet, allows the contractor and homeowner to connect the boiler to our platform. This gives the contractor the power to monitor, adjust and troubleshoot the boiler without having to go to the jobsite. NTInet will also send push notifications to alert customers that it’s time for service or there is a problem. Often the contractor will know about a problem before the homeowner does. NTInet is available on our TRX, FTVN and TFTN models. The TFTN also features a dynamic 7-inch touch screen and very powerful Set Up Wizard.

—Dave Walsh, Vice President Sales, NTI-USA 

RBI has a lot going on in our R&D Center. We are constantly evaluating existing product solutions in unison with new equipment opportunities that stay ahead of the changing dynamics of the industry as it relates to not only performance efficiencies but also environmental concerns. We have two new high-performance units coming to market in 2023 ranging from 300-1,000 MBH, a firetube boiler and a watertube boiler and water heater with improved true turndown, emissions and overall performance. These units will also complement existing equipment and broaden our spectrum from a size perspective. We will also be introducing several performance improvements to our existing equipment offerings, further increasing true turndown as well as optimizing flame sensing technology allowing us to not only improve overall performance but also emissions and the all-important carbon reduction footprint. These new technologies will work in perfect concert with our existing designs as it relates to burner configuration and our integrated control platform.

—Matt Kleszczynski, Director of Marketing, RBI 

RCB Series Commercial Wall Hung Boiler is available in 301k and 399k BTU sizes. The RCB comes with a stainless-steel heat exchanger, ultra-low Nox emissions certification, Wi-Fi remote access, BMS connectivity and easy access for service through three side removable panels. These boilers come with industry-leading 97% thermal efficiency and feature 7-inch color touch screen for easy navigation and troubleshooting. This new commercial boiler is expected to be available in Q4 2023. … Rinnai Central App is the newest Rinnai mobile application that allows the installing contractors to order parts, access technical documents, use a sizing calculator and set up customer’s mobile application without having to access their personal mobile devices. The new app’s official launch is planned for March 2023. Other Rinnai recent new product developments include redesigned RE tankless water heaters (additional models, higher UEFs, newer controls and accessories) and an upgraded D Series of EnergySaver Direct Vent Furnaces featuring advanced modulating technology, Wi-Fi thermostat capability, compact size, enhanced timer capability, newer display panel and a couple of new venting features.

—John Kopf, Sr. Product Manager, Innovation, Rinnai 

Thermal Solutions’ stackable high-efficiency products do not require external racking and include rugged and sturdy jacketing vs. sheet metal enclosing a box. We can place twice the BTUs in the same floor space and large applications such as hotels, resorts and malls love this concept.

—Jim Schnorr, Vice President of Sales, Thermal Solutions 

U.S. Boiler Co. keeps building on the unprecedented success and timesaving performance of Alta condensing boilers and combis. The company has completed the residential boiler and combi range between 80 MBH and 200 MBH and given mountain west customers favorable altitude derates that fit exactly in that range. All models either include or offer a practical, timesaving primary/secondary piping kit. USB Connect is an innovative new technician smartphone app and boiler interface. It speeds installation and service of current and legacy U.S. Boiler condensing boilers. USB Connect includes status reporting, installation guidance, diagnostics and the ability to perform active adjustments in real time. An online portal will also be available to help contractors view the details of their previous installations of U.S. Boiler condensing products.

—David Hansen, Residential Product Marketing Manager, U.S. Boiler Co.  

Velocity Boiler Works will be adding an 80 MBH input heat only boiler to our Phantom II lineup of residential condensing heat only boiler and combi boiler offering. We are also introducing PAT Connect, a smartphone app that when connected to the boiler through a Bluetooth interface assists the installing/servicing contractor with the set-up and servicing of a Phantom II boiler. Information can be saved to an online portal for future reference. The app will also be compatible with other our other existing condensing boilers.

—Lee Ensminger, National Sales Manager, Velocity Boiler Works 

Weil-McLain’s latest developments include our enhanced Weil-McLain ProTools App, the ECO Tec Series 2 residential boiler, and the expansion of our Stainless Vertical Firetube (SVF) boiler portfolio. Available for iOS and Android devices, the ProTools App now allows contractors and service technicians to work virtually with our Tech Support team to problem-solve issues as they occur. Heating professionals who run into complications while on the job can contact Tech Support for Site-Call video and receive immediate real-time assistance. After requesting support, they simply accept the call from Tech Support on their smartphone, share a live video of the issue they are experiencing and allow the support team to highlight the issue on their screen and propose corrective action to solve it. Not only does this new feature provide heating professionals with immediate access to support, but it also provides an opportunity to learn new methods for troubleshooting, maintenance and boiler setup. Featuring the same components, design advantages, features and accessories as the original ECO Tec unit, the ECO Tec Series 2 high-efficiency residential boiler features integrated control software that allows for multiple boiler configurations without the need for a third-party control component. With an optional multi-boiler wiring kit, users can connect and operate up to eight units simultaneously to satisfy the needs of larger structures like homes or apartment buildings. The Series 2 is also compatible with our ProTools App via Bluetooth, which allows contractors and technicians to view operational logs that provide trending data for monitoring system performance and detailed information for potential fault conditions. A user-friendly dashboard, fault and warning lookup, software update options and a “clone to phone” setting that can copy settings from one boiler to another make installation easier. Designed to meet the demanding needs of residential replacement applications, the ECO Tec Series 2 features a 95% AFUE rating, a long-lasting stainless steel fire tube heat exchanger and built-in zone control and heating system presets. We have also added five new sizes to our advanced, energy efficient SVF boiler portfolio for commercial heating applications. Joining the existing 1,500, 2,000, 2,500 and 3,000 MBH input configurations are 500, 600, 725, 850 and 1,000 MBH models that are ideal for both small and large commercial projects such as schools, colleges and other educational facilities, municipal buildings, multifamily, healthcare, churches and more. Featuring up to 98% thermal efficiency and unrivaled ease of installation and maintenance, the SVF boiler line was developed with contractors in mind and meets all market-driven bid specifications for new construction projects. Additionally, the Unity 2 and Nuro control systems that come standard on the boilers reduce installation and set-up time, simplify overall heating system design, are equipped with remote monitoring capabilities, and improve control interface commonality and communication across the entire boiler line.

—Dave DeVries, Director of Product Management for Weil-McLain