Reference projects

A continuously operating plant needed to replace two high-precision heat exchangers without incurring extended shutdowns. Deadlines were strict, the installation could not afford errors, and the margin for improvisation was, simply, zero.

We received the original units, carried out an exhaustive measurement survey and verified thicknesses and geometry with precision. We did not merely replicate them: we identified opportunities for energy improvement and incorporated optimisations that increased their efficiency relative to the replaced equipment.

The exchangers entered service within the agreed deadline, enabling an orderly replacement without compromising production continuity. Improved thermal efficiency compared to the original units, with zero unplanned shutdowns. A major company in the sector, listed on the IBEX 35, that continues to trust us today.

A bioplastics production plant in the Netherlands needed a large gas-to-gas heat exchanger for its recuperative thermal oxidiser. The requirements were multiple and simultaneous: strict technical certifications, guaranteed thermal performance and on-time delivery. The reason was critical: if the gases were not cooled to the required temperature before reaching the bag filters, those filters would be irreversibly damaged, with a very high replacement cost.

BOIXAC designed a 621 kW gas-to-gas heat exchanger, specifically adapted to the process conditions and the installation's certification requirements. The unit ensures precise gas cooling before entry into the filtration system, protecting downstream components.

On-time delivery, certifications in order and thermal performance in line with specifications. The bag filters have operated within their safe temperature range since start-up, preventing a very high replacement cost. An international project that demonstrates BOIXAC's ability to meet technical and logistical demands outside Spain.

One of Spain's most emblematic metallurgical companies needed to recover the residual heat from its furnace off-gases. Energy was lost with every production cycle, and the objective was clear: harness it to preheat make-up air and reduce the plant's energy consumption.

BOIXAC designed and supplied a 3,603 kW industrial air preheater that recovers heat from the process gases and transfers it to the make-up air. A high-capacity unit designed to integrate into a continuous and demanding process, with strict durability and efficiency criteria.

The installation enables the recovery of energy that was previously dissipated, with a direct and measurable impact on the plant's consumption. In addition to the economic improvement, the project helped reduce the environmental footprint of one of the country's leading metallurgical companies.

A leading company in the Spanish food market had been struggling for some time with a problem it could not solve: the heat exchangers installed by another supplier were not working correctly. They contacted us looking for a real solution before the next planned plant shutdown.

We analysed the case from scratch, taking nothing for granted. The diagnosis confirmed a design flaw in the previous supplier's equipment that prevented correct operation. We proposed BOIXAC heat exchangers specifically optimised for the actual process conditions, and guided the client through the technical decision to the end.

We delivered the units at the exact moment of the planned shutdown. Performance was as expected from day one, putting an end to months of recurring issues. The client found in us something more than a supplier: a trusted technical partner.

Two large Spanish business groups — one from the food sector and one from the energy sector — needed to improve the efficiency of their unit heaters at a biogas plant. Operating conditions were particularly harsh: continuous exposure to slurry and an environment with a high load of suspended particles. This was not an environment for standard equipment.

BOIXAC designed and supplied a high-resistance industrial unit heater, specifically engineered to maintain its performance in this type of severe environment over time. Every construction detail responded to the actual conditions of the installation.

The unit performed exactly as anticipated. The client extended its confidence in us to subsequent projects at the same installation. Their verdict was direct: "This unit works like a dream."

A world-leading company in oilseed processing and vegetable oil and fat production needed to renew the economiser system on its boilers. The contractual terms left no room for error: financial penalties for late delivery and for insufficient thermal performance. Getting it right first time was non-negotiable.

BOIXAC supplied a competitively priced economiser system, incorporating a proprietary improvement over the original design: a removable system that facilitates periodic inspection and cleaning, reducing future maintenance time and cost. The coastal environment was taken into account in the choice of materials and design decisions.

Delivery on the exact agreed date, with no deviations. Thermal performance not only met the contractual specifications but exceeded them, avoiding the contractual penalties. When contractual pressure is at its peak, the only valid answer is the result.

A dairy processing plant suffered a heat exchanger failure due to severe corrosion caused by the process brine. Production stopped immediately. Every hour of downtime had a direct cost, and the client needed a new unit with the utmost urgency.

BOIXAC designed and supplied a gasketed plate heat exchanger in high-purity titanium — the material with the greatest resistance to chloride and brine corrosion in food process applications. From receipt of the order to delivery at the plant: 5 days.

Start-up without incident. The exchanger has operated free of corrosion problems ever since, with unplanned downtime reduced to zero in subsequent campaigns. Sometimes the right solution and the urgent solution are exactly the same thing.

A leading producer of high-quality industrial minerals wanted to modernise its processes and reduce energy consumption. The environment was dusty and demanding, with limited space that constrained any technical solution.

BOIXAC designed a system of multiple air-to-air heat exchangers, with inspection and cleaning access points adapted to the conditions of a high-particle environment. Each unit was sized to fit the available space without compromising performance.

The system recovers 1,184 kW of thermal energy that was previously lost. Return on investment was achieved in under 6 months. In addition, maintenance operations are now faster and simpler thanks to the direct-access design.

One of the world's largest oil, gas and petrochemical companies needed a cross-flow heat exchanger for a melamine plant designed to minimise its environmental footprint by utilising urea production waste. The required capacity was not high, but the demands were: every possible kW had to be recovered, within a complex process engineering framework and with first-class certifications.

BOIXAC developed a high-efficiency cross-flow heat exchanger, optimised for the specific process conditions. The supply included material certificates, welder certificates, welding procedure certificates, dimensional records and pressure test documentation — all the technical documentation required by a client of this calibre.

Delivery met all required technical and documentary specifications. A project in Asia with full certification that confirms BOIXAC's ability to operate at international scale to the most demanding standards.

A company specialising in pharmaceutical engineering and ethylene oxide sterilisation systems needed heat exchangers capable of working under extreme temperature conditions, meeting the hygiene, traceability and precision requirements of the pharmaceutical industry. There was no room for compromise on materials or dimensional tolerances.

BOIXAC supplied finned tube heat exchangers manufactured entirely in stainless steel, with full technical documentation and material traceability. Each unit was custom-designed and manufactured to fit precisely within the client's sterilisation systems.

The units operate within the parameters required by the pharmaceutical process. An active and recurring collaboration that demonstrates BOIXAC's ability to respond with rigour to the most regulated and demanding industries.

A European manufacturer of equipment for the electronics industry was looking for a reliable supplier of series heat exchangers to integrate into its machines for the North American market. Previous suppliers had not met its standards. The additional challenge was dimensional: the exchangers had to fit in very compact spaces, with millimetre-level tolerances.

BOIXAC took on the regular supply of continuous-fin heat exchangers, incorporating proprietary design improvements to facilitate integration into the client's machines. Every unit is manufactured with rigorous dimensional control to ensure an exact fit during the assembly process.

A consolidated recurring supply relationship, with zero dimensional incidents since the start of the collaboration. BOIXAC units travel integrated in precision machinery to the North American market.

A company in the laboratory reagents and chemistry sector had been dealing for some time with a problem the previous supplier had been unable to solve: the installed exchanger was becoming flooded with condensate, blocking the process. They asked us for a solution that could be installed without modifying any of the existing infrastructure — ducts, fans and connections had to remain intact.

We visited the installation to see the problem first-hand. The diagnosis was clear: the previous unit had not been designed for the actual process conditions. BOIXAC designed a 188 kW stainless steel finned tube heat exchanger with aluminium fins, optimised to prevent condensate accumulation and sized with millimetre precision to fit the existing infrastructure.

The new unit was installed without modifying any peripheral component. The condensate problem disappeared from the very first start-up, putting an end to recurring stoppages that were affecting the production line. A rigorous diagnosis and a bespoke solution resolved what a standard unit had been unable to.

The aerospace industry tolerates neither errors nor delays. A company in the sector needed a set of heat exchangers within an extraordinarily tight timeframe, with the added difficulty that the standard connection positions did not match the installation's integration requirements.

BOIXAC responded with an express delivery of the custom exchanger set, adapting the connection positions to enable direct integration into the aerospace line without compromising any technical specification.

The units entered service on schedule, with no additional intervention on the line. In a sector where the margin for error is zero, the response is either correct or it is nothing.

Replacing a heat exchanger in an existing industrial HVAC line is not straightforward. Dimensions, connections and performance must match precisely to ensure integration without additional intervention in the installation.

BOIXAC supplied a steam heat exchanger matched exactly to the original unit's specifications, enabling a direct drop-in replacement without modifying the existing infrastructure.

The line was restored to normal operation in the shortest possible time, with no additional intervention in the installation. No surprises, no unforeseen costs.

An OEM client in the industrial printing sector was operating with a heterogeneous fleet of heat exchangers: multiple technologies, suppliers and specifications that were generating operational inefficiencies and an unnecessarily high maintenance cost.

BOIXAC carried out a detailed analysis of the actual requirements and proposed a full unification, standardisation and optimisation of the entire fleet. Each unit was selected according to the actual process conditions, replacing unnecessary diversity with thermal and constructive coherence, and simplifying procurement for the technical, purchasing and assembly departments.

Fewer suppliers, fewer spare parts references and reduced maintenance time. Better equipment with less operational complexity. Sometimes, simplifying is the hardest improvement to achieve.

A food processing plant needed to regularly replace multiple heat exchangers, all 100% custom-made, in spaces with extreme physical constraints. With no margin for manoeuvre, any dimensional error meant a useless component.

BOIXAC carried out an on-site visit to study the actual conditions at each position. The result was a series of units fitted with millimetre precision, built to withstand the demands of an intensive, continuous food processing environment.

Units more cost-effective than the originals and of notably superior construction, with zero rejections due to dimensional fit issues. The client stopped worrying about those heat exchangers — which in an industrial plant is the best possible sign.

To recover energy from digester sludge in a wastewater treatment plant with extremely restricted underground access points. Neither the duct dimensions nor the fluid conditions left room for conventional solutions.

BOIXAC supplied a demountable double-pipe heat exchanger, suitable for insertion through the available openings in separate sections and assembled in situ. The demountable configuration also facilitates periodic cleaning operations, particularly relevant in sludge applications.

The unit was assembled in a hard-to-reach space and operated within the required parameters from day one, enabling energy recovery in a position that had seemed unfeasible.

Implementing a new drying system in a paper mill means managing multiple thermal streams simultaneously with very different technologies: live steam, flash steam and condensation. Each application demands a unit specifically designed for its conditions.

BOIXAC supplied a complete set of heat exchangers for the drying system: live steam exchangers, flash steam exchangers and condensers, each tailored to the specific conditions of its application point within the overall process.

3,265 kW of thermal exchange operating in a coordinated manner at a paper mill belonging to a major German group. A large-scale project that cemented a long-standing relationship of trust.

To replace a heavily deteriorated economiser in a hard-to-access space at a meat processing plant. The solution had to improve on the original unit's performance and, at the same time, facilitate future maintenance interventions in a poorly accessible position.

BOIXAC supplied and installed a compact demountable economiser that can be extracted without the need to move the gas ducts. Maintenance accessibility was a fundamental requirement from the outset, not an afterthought.

More compact, more efficient and maintenance-accessible: three simultaneous improvements over the unit it replaced, with a significant reduction in intervention time during periodic maintenance.

A client in the meat sector had accumulated frustrations with previous suppliers. Distrust was the starting point. The task was not only to solve a complex thermal problem, but to demonstrate with solid technical arguments that a different way of working was possible.

BOIXAC approached the project with rigour: justifying every decision on the basis of its own expertise, proposing concrete improvements and optimising the heat exchange system as a whole. The client was able to verify the technical coherence of what was being built at every stage.

From a sceptical client, BOIXAC became the reference supplier for the entire group covering the Iberian Peninsula, Denmark and Poland. Not every project is won on price. Some are won by demonstrating technical rigour.

Biogas purification is thermally demanding and technically complex: the cryogenic stages, biomethane separation and bioCO₂ liquefaction operate under very different conditions, with strict requirements for materials, leak-tightness and thermal performance. The client needed a partner capable of addressing the heat exchange part with genuine precision.

BOIXAC carried out a precise analysis of the requirements and organised a visit to the facilities to demonstrate its procedures and technical capabilities. The solution combined coaxial and pillow plate technology, selected and adjusted for each stage of the process.

An active collaboration on large-scale projects in the renewable energy sector in France, where the thermal complexity of the process required a supplier with specific expertise in cryogenics and biomethane.

A research system operating in an argon-inerted atmosphere, with controlled oxygen presence and hydrogen sulphide (H₂S) generation, demands absolute leak-tightness throughout the thermal circuit. Any leak, however small, carries serious safety implications.

BOIXAC supplied a high-precision unit developed in collaboration with one of Europe's leading industrial pump manufacturers: a pressurised heat exchanger with absolute leak-tightness, optimised to achieve maximum performance under the specific conditions of the research process.

The unit has operated without incident since start-up, meeting leak-tightness requirements in an environment where safety admits no margin. A project combining maximum technical demands with a cutting-edge research application.

An OEM client needed a heat exchanger that matched the original equipment precisely: same dimensions, same connections, same thermal performance. In the OEM market, a deviation of just a few millimetres invalidates the integration.

BOIXAC studied the original equipment's specifications and supplied a precise, compact solution with exhaustive dimensional and thermal verification on every unit.

The unit fitted and performed to specification. The client placed repeat orders on a recurring basis. In the OEM market, consistency between what is promised and what is delivered is the factor that builds loyalty.

One of the largest industrial bakeries in northern France needed a regular and reliable supply of heat exchangers, each adapted precisely to the existing installations. Every position had its own dimensional and thermal constraints.

BOIXAC established a case-by-case analysis and adaptation process, studying each exchanger according to its position and actual process conditions, guaranteeing direct integration without modifications to the installation.

A consolidated regular supply partnership with one of France's leading industrial bakery groups, with no integration incidents in any of the positions supplied. Baguettes with a little of our know-how baked in.

An unexpected plant incident forced a client in the canned goods sector — one of the most recognised brands in the Spanish market — to urgently source a replacement economiser. Delivery had to coincide exactly with the scheduled shutdown window: any deviation would mean extending the production stoppage.

BOIXAC activated an urgent supply, coordinating delivery to match the exact plant shutdown date. Logistical planning was as important a part of the project as the engineering of the unit itself.

The plant resumed activity on schedule, avoiding an extended shutdown that would have meant a direct production cost. An effective response at a critical moment that gave rise to a lasting relationship of trust.

An energy installation exposed to outdoor conditions, with suspended particles present, required a thermal exchange system capable of operating continuously in adverse environmental conditions without degrading due to outdoor exposure or dust accumulation.

BOIXAC supplied a complete system: thermal insulation, bare tubes, fins, transition hoppers from rectangular to circular section and all elements necessary to ensure reliable operation in a dusty outdoor environment.

The installation has operated without incident since start-up in an adverse outdoor environment. The client has returned to BOIXAC for new projects.

Recovering energy from industrial kitchen exhaust gases is a challenge with narrow margins: variable flow rates, gases laden with particles and grease, and performance that depends on a very precise match to the actual operating conditions.

BOIXAC supplied a recovery system optimised to extract the maximum possible performance at every stage. The unit was selected and adjusted to match the actual operating profile of the installation, taking into account flow rate variability and the nature of the gases.

30 kW recovered continuously that were previously being lost up the flue. In energy efficiency, sustained gains over time translate into a real and cumulative economic impact.

To improve heat recovery from the flue gases of an industrial natural gas boiler at a Portuguese food plant, updating the existing technology and facilitating periodic maintenance operations.

BOIXAC supplied an economiser with an integrated extraction system that enables cleaning and inspection operations quickly and safely, without the need to immobilise the installation for extended periods.

Improved thermal recovery and reduced time required for maintenance operations, with a positive impact on both energy efficiency and plant availability.

A dual heat recovery system with strict technical constraints: fully certified materials, welder and welding procedure traceability, and two simultaneous recovery lines with very demanding thermal criteria.

BOIXAC supplied the system with thermally optimised construction and complete technical documentation: material certificates, welder certificates and welding process certificates, with full traceability. Every technical decision justified and documented.

1,000 kW of recovery operating across two simultaneous lines, with a complete quality dossier and zero incidents at start-up. When technical and documentary requirements must be met simultaneously, you need a supplier that manages both with equal rigour.

An industrial packaging plant urgently needed a heat exchanger adapted to the available dimensions and capable of handling variable flow rates under actual process conditions.

BOIXAC supplied a demountable shell-and-tube heat exchanger, precisely matched to the available space and designed to facilitate periodic maintenance without intervening in the rest of the installation.

The urgent need was resolved within the required timeframe, with the unit operating correctly under the anticipated process conditions from the very first start-up. The client has established BOIXAC as its go-to reference for heat exchange requirements.

To recover energy from a tank with a high content of viscous oils, in a system with severe space constraints. The fluid characteristics and available dimensions demanded an exchange geometry that maximised contact surface area within the available volume.

BOIXAC supplied a removable pillow plate heat exchanger, with a double-embossed surface suitable for viscous fluids and a configuration that allows maintenance without modifying the rest of the hydraulic installation.

200 kW recovered from a fluid that had previously been dissipating that energy without utilising it. An application where pillow plate geometry proved to be the right technology for the specific process conditions.

A boilermaking manufacturer needed finned tubes for a heat exchanger positioned in a non-submerged trough, with the objective of creating a cold barrier capable of condensing a highly volatile product and limiting its evaporation. A highly specific application requiring a precise fin geometry and precise materials.

BOIXAC supplied finned tubes adapted exactly to the required dimensions and thermal characteristics. Geometry, fin pitch and materials were selected for the specific conditions of the product and the process.

The tubes met the client's functional expectations, acting as the critical component that determined the performance of the complete unit. A collaboration where precision in geometry and material selection was decisive.

To recover thermal energy from the gases of an industrial iron and steel furnace for the French plant of one of the world's largest groups in the sector, with operations in Switzerland, the USA, Germany, the Czech Republic, Canada, Slovakia, Mexico, China and Spain. The technical and documentary standards of a group of this scale admit no exceptions on grounds of geography or order volume.

BOIXAC supplied a custom demountable heat recovery unit, adapted to the thermal and constructive parameters of the installation, meeting the client's technical and documentary requirements in every respect.

A collaboration with a multinational group present in 10 countries that confirmed BOIXAC's ability to operate to the most demanding standards regardless of order size or geographical location.

To thermally control 23 tanks holding up to 142,000 litres of syrup for cava production, complying with food contact regulations (FCM) and minimising welds in areas exposed to the product to reduce hygiene risk and facilitate cleaning.

BOIXAC supplied multiple AISI 316L electropolished coils, minimising welds and fully complying with all applicable FCM regulations. Each coil was tailored to the access opening, dimensions and conditions of each individual tank.

Precise thermal control across all 23 tanks, with a direct impact on the consistency and quality of the final product. All FCM requirements met in a large-volume installation.

A major cellulose plant with facilities in Asturias and Galicia needed to track multiple steam heat exchangers, integrating document management and the ordering process into the client's SAP Business system.

BOIXAC adapted to the client's internal processes, including the integration of traceability and procurement management via SAP Business, to facilitate tracking and documentation at a plant with structured purchasing processes.

A stable and continuous supply relationship with a reference industrial plant in the cellulose sector, with full integration into its internal management systems.

To replace existing units at a French paper mill while improving construction and thermal efficiency, but maintaining the exact overall dimensions and connection positions to avoid any modification to the existing infrastructure during the scheduled summer shutdown.

BOIXAC supplied three heat exchangers with AISI 304 stainless steel tubes, suitable for condensate service and high thermal efficiency, respecting the original dimensions and connections exactly. Delivery was made within the timeframe set for the summer shutdown.

Thermal and constructive improvement over the original units, with no modification to the existing infrastructure. The replacement was completed entirely within the available shutdown window.

To replace an existing heat exchanger at an automotive plant while improving thermal efficiency and durability, maintaining dimensional and connection compatibility with the in-service installation to avoid additional modifications.

BOIXAC designed and supplied a tube-and-fin heat exchanger with advanced thermal verification using specialised software (Unilab Coils), which confirmed a genuine improvement over the replaced unit, not merely a like-for-like replacement.

The unit exceeded the thermal performance of the original, verified with specialised software prior to start-up. The client has continued working with BOIXAC on subsequent projects.

Electrolytic polishing of jewellery requires precise thermal control of the electrochemical bath. The unit had to integrate into the limited space of an electropolishing installation without compromising exchange capacity or process safety.

BOIXAC supplied a high specific-capacity, compact-format pillow plate heat exchanger, suitable for thermal control of electrochemical baths in jewellery electropolishing installations.

Stable thermal control of the electrochemical bath in a confined space, with a direct impact on the quality of the parts' finish. An unusual application where pillow plate technology proved to be the right solution.

To recover residual energy from boiler flue gases at a winery, with a unit that would allow the plant's own staff to carry out periodic cleaning and maintenance operations without requiring external technical assistance.

BOIXAC supplied an economiser with an access drawer that allows the unit to be dismantled, cleaned and reassembled quickly. Accessibility for autonomous maintenance was a defining requirement in the configuration selection, not an optional extra.

Plant staff carry out maintenance autonomously, eliminating the cost and dependency of external technical assistance at every periodic service. At a plant with seasonal activity, this operational value is direct and measurable.

Electrolytic polishing of jewellery requires precise thermal control of the electrochemical bath. The unit had to integrate into the limited space of an electropolishing installation without compromising exchange capacity or process safety.

BOIXAC supplied a high specific-capacity, compact-format pillow plate heat exchanger, suitable for thermal control of electrochemical baths in jewellery electropolishing installations.

Stable thermal control of the electrochemical bath in a confined space, with a direct impact on the quality of the parts' finish. An unusual application where pillow plate technology proved to be the right solution.

A heat recovery system for a diesel boiler with high working pressure and condensation risk in the flue gases, which also required structural support for the additional weight of the chimney and a complete quality dossier with documented pressure tests.

BOIXAC supplied an economiser with an extraction system for cleaning, structurally dimensioned to support the additional chimney load, with exhaustive quality checks, pressure tests and a complete technical dossier.

A unit in service simultaneously meeting pressure requirements, structural support, maintenance accessibility and complete technical documentation — three simultaneous requirements, all resolved.

The installation required a thermal exchange unit adapted with extreme precision to the dimensions of an existing position, in an industrial ceramics environment with high mechanical demands. Standard tolerances were not applicable.

BOIXAC supplied a pillow plate heat exchanger fitted with strict dimensional precision to the existing measurements, with high mechanical resistance for the conditions of the industrial ceramics environment.

The unit was integrated into the existing installation without any additional modification. An active collaboration with one of Spain's largest ceramics groups where dimensional precision was the decisive factor.

An economisation system for flue gas heat recovery at a food processing plant in North Africa. The unit had to provide structural support for the additional weight of the chimney and incorporate an extraction system enabling regular hygiene cleaning and maintenance by local staff.

BOIXAC supplied a finned tube system with an integrated extraction drawer to facilitate periodic hygiene cleaning. The structural chimney support was incorporated into the unit assembly, eliminating the need for separate reinforcing elements.

A project executed on the African continent to the same technical and quality standards as any other BOIXAC project. Geography does not alter standards.