Challenge: An Aging Boiler System Threatening Winter Production

United Materials, a ready-mix concrete producer operating under the VCNAR umbrella near Buffalo, New York, faced limitations with its aging boiler system. Its internal equipment room was no longer viable for replacement installations due to structural constraints. To modernize their heating capabilities and improve wintertime production reliability, the company partnered with Kemco to implement a portable, turnkey direct contact water heater (DCWH) system.

The customer’s existing boiler system, installed inside a dated facility, posed several challenges.

Structurally, the old boiler could not be removed without being cut apart and installing new equipment in its place, which would have required partial demolition of the building. From an operational standpoint, the legacy boiler was highly inefficient, operating at an estimated 40 to 50 percent efficiency. This inefficiency resulted in excessive fuel consumption and inconsistent hot water output. Compounding the issue, the lack of reliable hot water placed winter concrete production at serious risk, with the potential for full shutdown during cold months.

Solution: A Portable System That Bypassed Structural Constraints

Kemco is the leader in Direct Contact Water Heater design, which this facility turned to for our historically trusted technology. In 1978, Kemco introduced the first direct contact water heater and has maintained its industry leading reputation ever since as it continues to service the food processing industry with sanitation needs. Food processing facilities need hot water on demand and as needed for sanitation. The Kemco DCWH allows for on-demand hot water stored or direct-to-process. Two DCWHs were installed for a fully redundant system for ease of future maintenance and emergency hot water needs at this facility.

Direct Contact Water Heater in warehouse
Direct Contact Water Heater from Kemco

Meeting State Environmental Product Declarations (EPD) Regulations with an ROI

As of January 2025, concrete producers operating in New York face new reporting requirements under the state’s recently adopted Buy Clean Concrete guidelines. Producers are required to submit Environmental Product Declarations (EPDs) for concrete mixes used in state agency projects valued at more than $1 million and involving 50 cubic yards or more of concrete, or New York Department of Transportation projects valued at more than $3 million and involving 200 cubic yards or more. In addition to submitting EPDs, producers must also ensure their concrete mix designs meet established Global Warming Potential (GWP) thresholds, currently set at 150% of regional baselines, to help reduce embodied carbon in public construction.

An EPD is a standardized, third-party-verified document that quantifies the environmental impact of a product over its life cycle, commonly referred to as its “carbon footprint.” EPDs detail emissions associated with raw material extraction, manufacturing, transportation and other lifecycle stages. Often compared to a nutrition label for construction materials, EPDs provide transparent data that designers, specifiers and project owners can use to make informed decisions about sustainability and meet regulatory requirements.

To assist concrete producers in meeting EPD regulations set by New York State, the Kemco DCWH reduced overall energy usage by approximately 50-60%, thus lowering the embodied carbon footprint of the concrete production process and supporting compliance with state GWP limits.

Sustainable Heating System Design

At the core of the new system is a high-efficiency direct contact water heater that delivers 99.7 percent thermal efficiency, dramatically improving performance and reducing fuel consumption compared to the previous boiler. The solution was not only technically effective but also proven in the field. In a continuation of an existing relationship, United Materials had already installed a Kemco system at another facility, which had been operating reliably for five years. United Materials once again trusted Kemco to manage this operational change knowing the Kemco team’s ability to customize unique solutions for any project.

Kemco delivered a pre-engineered, containerized, turnkey package for this United Materials project. Unlike previous installations with other ready-mix clients in which the customer self-installed, Kemco managed all aspects of the project, from equipment supply to installation. The system design prioritized mobility, ease of connection and minimal site disruption.

The key feature of this customized system was a fully containerized design, which eliminated the need to retrofit or modify the existing boiler room. By housing all equipment, such as the direct contact water heater, pumps, controls and piping within a purpose-built portable container, the solution avoided costly demolition or reconstruction work. This containerized format not only streamlines equipment delivery and setup but also allows for relocation or modular expansion in the future.

The Kemco DCWH Advantage

United Materials ultimately chose the Kemco DCWH for its thermal efficiency versus traditional boiler systems. Unlike traditional boilers, which transfer heat through metal surfaces, the direct contact method brings water into direct contact with the combustion gases, allowing nearly all the heat to be transferred into the water. This results in dramatically improved fuel utilization, lower operating costs and consistent hot water output. This higher output is especially critical for applications with high or variable demand.

Furthermore, additional benefits of this installation were realized through system redundancy and parts commonality. By standardizing equipment across multiple locations, the company could share spare parts and streamline maintenance procedures. Choosing Kemco’s turnkey package also brought significant operational advantages. United Materials avoided the need to hire a licensed boiler operator and eliminated the requirement for annual boiler inspections, thereby reducing both labor costs and regulatory compliance burdens.

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