The integration of specialised expertise with advanced technology is increasingly shaping industrial performance. This trend is evident in two recent projects completed by boiler operations and maintenance specialist Associated Energy Services (AES) within the food manufacturing sector.
According to AES Commercial Director Dennis Williams, consistent data collection and interpretation are essential for improving efficiency and productivity in boiler operations. Remote monitoring systems (RMS) play a critical role in ensuring safe and effective management.
“AES adds value by identifying and anticipating potential issues. By combining control systems, remote monitoring and human expertise, we prevent downtime, enhance operational efficiency and control costs, while supporting complex production environments,” he explains.
Two projects, one approach
The first project involved a long-term food processing client with an ageing boiler control system that had become expensive to maintain. AES was tasked with upgrading the system while retaining parts of the existing infrastructure.
Initially, the plan was to upgrade one boiler and roll out the solution to the remaining units after proving its effectiveness. However, during the year-end shutdown, the client opted to upgrade all three boilers simultaneously—placing significant time pressure on AES.
Despite the tight deadline, the upgrades were successfully completed, with additional commissioning and optimisation carried out after start-up. A major improvement was the introduction of load balancing across all three boilers, ensuring that no single unit was overburdened.
The second project, for a new client in the food sector, required a fully customised control and RMS solution. AES developed a system featuring a web-based interface for real-time monitoring, performance tracking and data analysis.
Although built on AES’s core control philosophy, the system was tailored to meet specific operational requirements. Different sections of the plant required varying steam pressures at different times, and the solution incorporated multiple operating modes to accommodate this.
Supply chain disruptions presented additional challenges, forcing AES to shift from factory-based assembly to on-site completion.
“We prioritised getting the standby boiler control system operational so the plant could restart, especially as the active boiler was experiencing issues. Our goal was to provide the redundancy needed for reliable steam supply, and we adjusted our planning to deliver as quickly as possible,” explains AES Projects Director Gavin Evezard.
Data-driven decision-making
Both projects highlight the increasing importance of data in operational decision-making. RMS platforms allow management teams to monitor performance, investigate anomalies and conduct detailed root cause analyses.
By analysing metrics such as fuel consumption, emissions and steam pressure, operators can ensure optimal performance and reliability.
“When issues arise, we can review historical data to understand exactly what happened. This enables accurate root cause analysis and helps prevent future incidents,” says Evezard.
In the second project, AES introduced additional performance metrics tailored to the client’s needs, including comparisons between manual and automated operating modes and detailed fuel consumption analysis.
Evezard notes that such flexibility is particularly valuable in South Africa, where many industrial boilers are decades old.
“A large portion of the installed boiler base is between 30 and 60 years old. In many cases, original equipment manufacturers no longer provide support or software, and are based overseas, making assistance costly. Our in-house systems and expertise allow us to diagnose and resolve issues locally, reducing downtime and associated costs,” he explains.
The human factor remains critical
Despite advances in automation, both Williams and Evezard stress that human involvement remains essential—especially when working with solid fuel boilers.
“Control systems can only go so far. Operators still need to perform checks and configure boilers according to production requirements,” Evezard says.
Williams adds that human oversight is also vital for maintaining safety standards.
“If systems become too automated, critical safety considerations may be overlooked. Ongoing human supervision helps mitigate risks associated with combustion and pressurised steam systems,” he notes.
Delivering long-term value
Beyond immediate efficiency gains, AES views these projects as the foundation for long-term client partnerships. Williams points out that more than 75% of boiler upgrade projects evolve into ongoing service agreements.
“Each project effectively becomes a proof of concept for future collaboration,” he says.
Measurement and transparency are central to this approach. By providing clients with clear, data-driven insights into their operations, AES demonstrates tangible value and builds trust.
The enhanced visibility offered by AES’s control systems and RMS platforms often transforms how clients view their steam operations.
“Many clients don’t fully realise that steam delivery involves the complete process—from fuel conversion to distribution and utilisation. Our systems provide that visibility, helping them understand and optimise the entire process,” Williams concludes.