Cut Warm Air Heating Costs with Optiburner

Reduce energy waste, stabilise indoor temperatures, and improve the efficiency of your warm air heaters with proven optimisation technology — without replacing your existing equipment.
White rectangular industrial warm air heater unit suspended from a ceiling in a warehouse.
Optiburner warm air heater optimisation helps you reduce fuel consumption, improve heat distribution, and minimise costly cycling across large spaces. With measurable efficiency gains, increased comfort, and enhanced plant longevity, it’s the smart way to lower your heating costs and strengthen your operational performance.

Energy savings

Cut heating costs by reducing burner cycling and improving warm air heater efficiency across large commercial, industrial, and open spaces.

Improved comfort

Enhance thermal comfort by reducing stratification and ensuring warmer air is distributed evenly throughout high-ceiling or open-plan heated spaces.

Extended lifespan

Minimise mechanical wear by reducing frequent stop-start heating cycles, helping warm air heater components operate more reliably and last longer.

Rapid installation

Integrates seamlessly with existing warm air heaters for quick, non-disruptive installation, allowing operational savings to begin almost immediately.

Understanding warm air heater optimisation

Traditional warm air heaters often continue operating even after reaching maximum temperature, leading to unnecessary fuel consumption and reduced efficiency. Without built-in temperature modulation, the burner cycles excessively, overheating internal chambers and releasing valuable heat through flue losses. This uncontrolled operation increases running costs and makes it difficult to maintain consistent comfort.
Diagram of a warm air heater showing incoming room air entering at the bottom, heat transfer around a central combustion chamber with flame, outgoing warm air exiting on the sides, and flue gases leaving at the top, with a note indicating no thermostat control.

How warm air heaters operate in large spaces

Warm air heaters draw in cool air, heat it within the combustion chamber, and distribute it across large areas such as warehouses, production sites, and sports facilities. These systems are designed to push substantial volumes of warm air into high spaces where constant airflow is needed.

However, their performance depends heavily on the size and shape of the building, as well as how the heat behaves once released into the environment. Without optimisation, a significant proportion of warmth rises quickly, leaving working areas cooler and placing additional demand on the heater to maintain comfort.
Problem

Because warm air heaters fire at a constant rate, excess heat often accumulates within the combustion chamber before being expelled through the flue. This wasted thermal energy has no opportunity to contribute to space heating, increasing fuel consumption while providing minimal additional comfort across large commercial environments.
Solution

Optiburner resolves this by monitoring internal temperatures and adjusting firing behaviour to prevent unnecessary heat build-up. By extending cooling periods and using residual warmth more effectively, the system ensures a greater proportion of generated heat is delivered into the building, improving efficiency without requiring new equipment or structural changes.
Result

By optimising firing intervals and recovering otherwise wasted residual heat, Optiburner achieves measurable efficiency gains. Improved heat transfer, reduced flue gas losses, and more stable cycle control allow warm air heaters to deliver consistent temperatures using less fuel. Businesses typically experience energy savings of 20–30% alongside improved overall heating performance.
Graph with temperature on the vertical axis and time on the horizontal axis showing a red curve rising and then flattening at maximum temperature; text below states the problem as air reaching maximum temperature while the burner keeps operating.

Why warm air heaters waste unnecessary energy

Warm air heaters often operate longer than necessary because they cannot regulate internal temperatures effectively. Once heat is generated within the chamber, the system continues to fire regardless of actual demand. This uncontrolled behaviour increases fuel use, places additional strain on components, and makes efficient temperature management difficult across large heated spaces.
Problem

As the chamber temperature reaches its maximum threshold, traditional heaters cannot detect that sufficient heat already exists. With no modulation capability, the burner continues operating, producing heat the building cannot immediately use. This leads to excessive fuel consumption, higher flue temperatures, and unnecessary thermal stress, all without improving comfort at occupied levels.
Solution

Optiburner solves this issue by monitoring internal temperature peaks and interrupting burner activity before unnecessary firing occurs. By aligning heating cycles with actual demand and allowing controlled cooling periods, the system prevents overshooting, reduces wasted flue heat, and maintains dependable operation while significantly lowering the fuel required to sustain comfortable temperatures throughout the building.
Result

By interrupting burner operation at the correct temperature point, Optiburner prevents overshooting and unnecessary heat release. This reduces chamber stress, limits wasted flue energy, and delivers measurable performance gains. Many sites achieve significant reductions in fuel consumption while maintaining steady, demand-led heating throughout long operating periods.
Diagram of a warm air heater with labeled warm air control showing internal flame and airflow with arrows indicating warm air flow and 20-30% energy savings.

How Optiburner intelligently optimises warm air heaters

Warm air heaters generate substantial warmth but often lack the ability to regulate how that heat is delivered. Optiburner enhances this process by monitoring internal temperatures and actively controlling firing behaviour. By intelligently managing each burn cycle, the system ensures heat is produced, stored, and released in a more efficient and controlled manner across large spaces.
Problem

Without internal temperature sensing or cycle optimisation, warm air heaters fire according to basic thermostat commands rather than real heating demand. This causes rapid, repetitive burner restarts that ignore stored thermal energy within the chamber. The resulting short cycles waste fuel, limit usable heat output, and reduce the heater’s overall operational efficiency and reliability.
Solution

Optiburner introduces intelligent cycle control by measuring chamber temperatures and calculating the optimal moment to begin or pause combustion. By coordinating burner activity with fan operation and utilising residual heat, the system extends cycle length, reduces unnecessary firing, and creates a steadier, more efficient heating pattern tailored to the building’s requirements.
Result

This refined control process improves heat transfer and significantly reduces flue gas losses by allowing more of the generated heat to be circulated through the building. With smoother, longer burn cycles and reduced thermal waste, businesses benefit from greater comfort and stability, improved heater responsiveness, and measurable reductions in fuel consumption throughout daily operations.
Two transparent house-shaped diagrams comparing temperature distribution with and without warm air control showing cooler and more even temperatures with control.

Real-world improvements in thermal stratification

In buildings with high ceilings, warm air naturally rises and accumulates overhead, creating a pronounced temperature difference between roof and floor levels. This uneven heat distribution forces heaters to operate longer and harder to maintain comfort near ground level. As a result, energy consumption increases while heating performance becomes inconsistent throughout large commercial environments.
Problem

When heated air collects at elevated heights, the lower occupied zones remain significantly cooler, prompting the heater to continue firing even though excessive warmth is trapped above. This inefficient temperature layering not only wastes fuel but also prevents the system from delivering stable comfort, especially in warehouses and other expansive, vertically open spaces.
Solution

Optiburner corrects this imbalance by optimising burner operation and encouraging more effective movement of conditioned air. By preventing excessive heat accumulation at ceiling level and promoting a flatter temperature profile, the system reduces unnecessary firing loads. This targeted improvement helps warm air heaters operate efficiently while maintaining consistent comfort across large, stratification-prone environments.
Result

Improved thermal balance reduces the height-to-floor temperature gap, allowing heaters to deliver warmth exactly where it is needed. Lower ceiling temperatures, combined with steadier airflow, reduce the system’s overall workload. These changes translate into reduced fuel consumption, enhanced comfort and stability, and a more efficient heating environment for buildings that previously suffered from severe stratification.

Unlock powerful efficiency gains with Optiburner

Optimising your warm air heaters with Optiburner transforms the way large commercial spaces manage heat, energy, and comfort. By improving internal heater efficiency, enhancing temperature control, and reducing unnecessary cycling, Optiburner delivers measurable savings without replacing existing equipment. From enhanced comfort to lower operational costs, these benefits create long-lasting value for every building that relies on warm air heating.

Enhanced internal heater efficiency

Optiburner improves the way warm air heaters manage heat inside the combustion chamber, reducing flue gas losses and stabilising the burner’s performance. By using stored heat more effectively, the system ensures each heating cycle delivers greater value, helping large spaces maintain consistent comfort while lowering fuel consumption.

Reduced burner cycling and fuel waste

Continuous stop-start behaviour forces heaters to consume more energy than necessary. Optiburner prevents excessive cycling by optimising the firing pattern, allowing longer, more efficient heat delivery. This lowers mechanical strain, minimises wasted fuel, and supports smoother heating performance throughout demanding operational periods.

Improved temperature balance and comfort

High-ceiling spaces often suffer from sharp temperature differences between floor and roof levels. Optiburner addresses this challenge by improving heat distribution, reducing thermal stratification, and creating a more even temperature profile. This ensures better comfort for staff, customers, and equipment-sensitive environments.

Long-term operational and cost benefits

By improving heater reliability and reducing unnecessary load on internal components, Optiburner contributes to a longer system lifespan and fewer maintenance issues. With fuel savings typically ranging from 20–30%, businesses benefit from rapid payback, predictable performance, and sustained reductions in overall heating costs.
Optimising warm air heaters with Optiburner results in clear, quantifiable performance gains. These core metrics demonstrate how intelligent cycle control, improved heat transfer, and reduced thermal losses translate into practical savings and enhanced comfort throughout large, high-demand spaces.
20 to 30%
Fuel savings
Up to 12°C
Lower ceiling temperatures
Up to 40%
Cycle reduction
3 to 12
Months payback period

"Optiburner reduced our heating expenses by almost 30% while maintaining comfort. The fast installation and immediate cost savings have made it an essential part of our energy efficiency plan."

Smiling young man with curly hair wearing a light blue shirt against a pale background.
John Smith
Facilities Manager

Tailored optimisation for every warm air heated environment

Warm air heaters are essential for maintaining comfort and productivity in large commercial spaces, but their performance varies greatly depending on the environment. Optiburner is engineered to optimise heater output across a wide range of industries, improving temperature stability, reducing energy waste, and delivering measurable fuel savings wherever warm air systems are in use.
Warehouse aisle with high shelves stocked with pallets and barrels, and three workers wearing safety vests and helmets managing inventory.

Warehousing & Distribution

Warehouses often experience rising heat and uneven temperatures. Optiburner improves air movement, reduces stratification, and lowers fuel use, delivering stable, efficient heating performance across busy distribution environments daily.
Read more
Worker wearing a red safety helmet operating a chain hoist to lift metal parts in a busy industrial warehouse.

Manufacturing & Production

Manufacturing sites require stable temperatures for equipment and staff comfort. Optiburner reduces wasted heat, improves warm air distribution, and maintains efficient, consistent heating performance throughout large production areas.
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Three female volleyball players in black sportswear in a gym, with one preparing to pass a volleyball.

Sports & Leisure Facilities

Sports halls and leisure centres lose warm air to high ceilings, creating discomfort. Optiburner improves circulation, reduces stratification, and maintains consistent, efficient heating performance across large recreational spaces.
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Indoor vertical farm with rows of green leafy plants growing under LED lights and a reflective wall.

Agriculture & Controlled Environments

Agricultural buildings rely on steady heating to protect livestock, crops, and equipment. Optiburner reduces wasted heat, improves temperature balance, and maintains efficient, consistent performance across large agricultural structures.
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Woman carrying shopping bags walking inside a brightly lit mall with glass ceiling and festive bunting.

Retail & Customer Spaces

Retail spaces often struggle with uneven temperatures from open layouts and door traffic. Optiburner improves heat balance, reduces wasted energy, and maintains efficient, consistent heating performance in shops.
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Warm air heater optimisation made easy

Optimising warm air heaters can significantly reduce running costs and improve comfort across large commercial spaces. Optiburner’s structured process ensures every stage is handled professionally, from the initial assessment to ongoing optimisation. Our approach simplifies the transition to a more efficient system, helping businesses achieve measurable energy savings with minimal disruption to daily operations.

Free consultation and system review

We begin with a free consultation to understand your heating setup, building layout, and operational requirements. This initial review helps identify how warm air heaters are currently performing and highlights where energy is being wasted. Our team then provides clear recommendations outlining how Optiburner can improve efficiency and reduce fuel costs.

Detailed site survey and heater assessment

Our engineers visit your site to examine heater condition, airflow patterns, and temperature distribution across the building. We capture accurate performance data to determine how heat behaves at height and floor level. This assessment confirms compatibility with Optiburner and ensures the optimisation strategy is tailored precisely to your facility’s unique requirements.

Professional installation and configuration

Optiburner is professionally installed on your existing warm air heaters without disrupting operations. Our engineers configure the system to monitor internal temperatures, refine burner cycles, and improve heat utilisation. Once installed, each heater is thoroughly tested to ensure stable performance, efficient operation, and reliable temperature control across your environment.

Ongoing optimisation and performance monitoring

Following installation, Optiburner continues refining heater behaviour through intelligent cycle control and improved heat distribution. Our team provides ongoing support to ensure consistent performance throughout the heating season. With more efficient operation and reduced fuel use, you benefit from sustained comfort, lower running costs, and long-term optimisation of your warm air heating systems.

Optiburner insights: What you need to know

We’ve gathered essential answers to help you understand how Optiburner improves the efficiency of warm air heaters. Whether you’re comparing costs, assessing compatibility, or exploring system benefits, these insights explain how optimisation enhances performance, reduces waste, and delivers measurable improvements across large commercial environments.
What does Optiburner actually optimise in warm air heaters?

Optiburner focuses on controlling burner behaviour within the warm-air heater’s combustion chamber. By monitoring internal temperatures and adjusting firing cycles, it prevents unnecessary burner operation and improves the use of generated heat. This targeted optimisation increases efficiency, reduces fuel waste, and helps heaters deliver more stable comfort across large commercial spaces.

How does Optiburner reduce wasted heat?

Warm-air heaters often continue firing even after generating enough heat, wasting valuable energy that could be used elsewhere. Optiburner prevents this by pausing burner activity when the optimal chamber temperature is reached, allowing the system to use stored heat more effectively. This significantly reduces wasted thermal energy across operating cycles.

How does Optiburner help with high-ceiling heat stratification?

High-ceiling buildings trap warm air near the roof, leaving floor areas cooler. Optiburner improves airflow and stabilises burner operation, reducing excessive ceiling temperatures. This promotes a more balanced heat distribution, enhances comfort at ground level, and lowers the extra fuel required to overcome severe stratification.

Is Optiburner compatible with older warm air heaters?

Yes. Optiburner is a retrofit optimisation unit that integrates with most commercial warm-air heaters, including older models. Compatibility is confirmed during the site survey, where engineers assess heater condition, airflow behaviour, and cycle patterns. As long as the heater operates safely, Optiburner can typically be installed successfully.

How quickly does Optiburner deliver measurable improvements?

Efficiency gains appear almost immediately because Optiburner prevents the heater from firing above the required temperature. Fuel savings become noticeable during the first weeks of operation, and stratification improvements follow as air movement stabilises. Many sites achieve meaningful reductions in consumption early on, with full payback commonly occurring within the first heating season.

How does Optiburner affect burner cycling?

Traditional warm-air heaters often cycle on and off due to basic thermostat control. Optiburner monitors internal temperatures and extends cooling periods to prevent premature burner restarts. This results in longer, more efficient burn cycles, fewer unnecessary stops, and a noticeable reduction in fuel consumption and mechanical strain.

Will Optiburner change how warm air is distributed in the building?

Yes. By regulating firing behaviour and reducing excessive heat at ceiling level, Optiburner encourages a more even temperature profile throughout the building. Improved distribution means less reheating is required to maintain comfort, helping large spaces stay warmer at floor level without increasing overall fuel consumption.

Does Optiburner reduce flue gas losses?

Warm air heaters often expel unused heat through the flue when firing continues past required temperature levels. Optiburner minimises this by adjusting cycle behaviour and ensuring heat is used efficiently before new combustion begins. This reduces flue losses significantly and improves overall thermal performance.

What types of buildings benefit most from optimisation?

Warm air heater optimisation is especially effective in buildings with tall ceilings, open layouts, and long heating hours. Warehouses, factories, logistics centres, sports halls, and agricultural environments typically experience the greatest gains because they suffer most from stratification, frequent cycling, and extensive flue heat loss.

Will Optiburner improve comfort for staff or building users?

Yes. By reducing stratification and creating steadier heat output, Optiburner helps maintain comfortable temperatures in the areas people occupy. This is especially valuable in warehouses, production spaces, and sports facilities where comfort is often inconsistent due to uneven heating and constant fluctuations in burner performance.

Is the installation process disruptive?

Installation is typically quick and completed while your heating system remains operational. Optiburner is fitted to the existing heater controls and calibrated on-site. Most installations require minimal downtime, allowing businesses to continue operating normally while gaining immediate improvements in efficiency and heating performance.

How does Optiburner support long-term heater reliability?

By preventing rapid cycling, reducing internal overheating, and stabilising temperature behaviour, Optiburner eases mechanical strain on warm air heaters. This leads to smoother operation, fewer stress-induced faults, and improved reliability across the heating season. Many users see reduced maintenance needs and longer component life as a direct result.

Unlock efficient, consistent heating with Optiburner

Optiburner transforms the performance of warm air heaters by reducing unnecessary burner operation, improving heat transfer, and lowering ceiling temperatures. By addressing the root causes of inefficiency—cycling waste, poor modulation, and stratification—Optiburner helps businesses achieve reliable comfort, stronger energy control, and measurable savings across large commercial and industrial environments.
Industrial boilers with large orange front panels and connected piping and gauges in a mechanical room.

Reduced energy waste

Optiburner prevents warm air heaters from firing unnecessarily by controlling internal temperatures and extending cycle duration. This reduces wasted heat, lowers flue losses, and ensures more of the energy generated is delivered into the building, creating measurable improvements in overall heating efficiency.

Better heat distribution

By limiting excessive heat build-up near the ceiling, Optiburner helps maintain a more balanced temperature profile throughout large spaces. This improves comfort at floor level, reduces heating demand, and enables warm air heaters to operate more effectively in tall or stratification-prone environments.

Rapid payback

Improved cycle control, reduced fuel consumption, and lower temperature imbalance allow Optiburner to deliver rapid financial returns. Many businesses recover their investment quickly and continue benefiting from ongoing energy savings enabled by intelligently controlled warm-air heater performance.

Ready to optimise your warm air heating?

Improve efficiency, reduce fuel waste, and stabilise comfort across your building with Optiburner’s proven warm air heater optimisation. Our team is here to assess your system, answer questions, and provide clear guidance on expected savings. Complete the form below to schedule your free consultation and discover your potential energy improvements.

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