Advancing Efficiency and Performance in Industrial Heating Systems

Across industries, combustion systems are at the heart of critical operations — powering boilers, furnaces, dryers, and process heaters that keep production running. Over time, these systems can become inefficient or fall out of compliance with evolving environmental regulations. Replacing an entire combustion system can be costly and disruptive, but there’s a smarter, more economical solution: a burner retrofit.

At Bacon Engineering, we specialize in delivering high-performance burner retrofit solutions that improve efficiency, reliability, and environmental compliance. With decades of experience in boiler control systems and combustion technologies, our engineers have the expertise to modernize your existing equipment and extend its operational life — while delivering measurable energy savings.

What Is a Burner Retrofit?

A burner retrofit is the process of upgrading or replacing the burner in an existing industrial or commercial combustion system. The burner — responsible for mixing fuel and air to generate heat — is one of the most critical components in a boiler or furnace. As technology advances, modern burners offer significantly improved combustion efficiency, safety features, and emissions control compared to older designs.

Instead of replacing an entire boiler or heating system, a retrofit focuses on installing a new, high-efficiency burner and integrating it with advanced control systems. This approach maximizes the value of existing infrastructure while providing the benefits of modern combustion performance.

Why Burner Retrofits Are Becoming Essential

Over time, even the best-maintained systems lose efficiency. Components wear down, controls become outdated, and emissions increase. Retrofitting your burner system addresses these challenges head-on.

Here are the key drivers behind the growing demand for burner retrofits:

1. Energy Efficiency Improvements

Modern burners are engineered for optimal air-fuel mixing and precise combustion control. These innovations can deliver fuel savings of 10% to 30%, depending on system conditions and application type. Improved efficiency means reduced operational costs and a faster return on investment.

2. Environmental Compliance

As emissions standards become stricter across North America, industries must take proactive steps to lower NOx (nitrogen oxides), CO (carbon monoxide), and unburned hydrocarbons. Retrofitted burners are designed to meet or exceed these regulations, helping facilities avoid costly fines while supporting sustainability goals.

3. Enhanced Process Control

New combustion control technologies — including oxygen trim systems, variable frequency drives (VFDs), and digital control platforms — allow real-time monitoring and adjustment of combustion conditions. This ensures consistent heat output, improved product quality, and reduced waste.

4. Cost-Effective System Renewal

A full system replacement can be expensive and disruptive. Burner retrofits, on the other hand, allow businesses to upgrade performance without replacing the entire system. This extends the life of boilers and furnaces while delivering comparable benefits at a fraction of the cost.

The Bacon Engineering Approach to Burner Retrofits

At Bacon Engineering, we take a comprehensive approach to burner retrofits — combining deep combustion knowledge with advanced control integration. Every project begins with understanding the client’s specific system, operating conditions, and performance goals.

1. System Assessment and Analysis

Our engineers conduct a detailed assessment of the existing equipment. This includes evaluating the burner, boiler or furnace configuration, air supply, fuel delivery system, and control mechanisms. We also analyze historical performance data, fuel consumption rates, and emissions output to identify inefficiencies.

2. Custom Design and Burner Selection

There’s no one-size-fits-all solution. We select or custom-engineer the ideal burner based on process requirements, fuel type, and system load. Our partnerships with industry-leading burner manufacturers enable us to provide low-NOx, high-efficiency, and multi-fuel burner options that align with your operational needs.

3. Control System Integration

A burner retrofit is most effective when paired with a modern control system. Bacon Engineering’s expertise in boiler control system design ensures seamless integration of advanced monitoring, modulation, and safety features. We implement controls that enhance automation, improve combustion tuning, and provide precise real-time adjustments for maximum efficiency.

4. Installation and Commissioning

Our field technicians handle all aspects of the installation, ensuring that every component is installed to code and optimized for performance. Once installed, we commission the burner and control systems through a rigorous testing process — fine-tuning air-fuel ratios, verifying safety interlocks, and calibrating sensors to achieve peak performance.

5. Training and Ongoing Support

We believe that a successful retrofit includes empowering operators. Bacon Engineering provides hands-on training for plant personnel, ensuring they understand system operation, maintenance routines, and troubleshooting. Ongoing technical support and performance audits help sustain long-term results.

Benefits of a Burner Retrofit

Choosing a burner retrofit through Bacon Engineering brings tangible, long-term benefits:

Fuel Efficiency: Achieve up to 30% reduction in fuel use through improved combustion and heat transfer.

Emission Reductions: Lower NOx, CO, and particulate emissions to meet or exceed regulatory standards.

Enhanced Safety: Updated safety interlocks and flame supervision systems reduce risks of failure or fire.

Improved Reliability: Modern components and controls minimize downtime and maintenance requirements.

System Longevity: Extend the operational life of your boiler, furnace, or process heater by 10–20 years.

Quick Payback: Most burner retrofit investments deliver ROI within 1–3 years through energy savings.

Industries Served

Bacon Engineering has successfully executed burner retrofits across a wide range of industries, including:

• Manufacturing & Process Heating – Retrofitting process furnaces for uniform heating and energy savings.
• Food & Beverage – Ensuring consistent product quality through precision temperature control.
• Power Generation – Upgrading burners in industrial boilers for efficient steam production.
• Chemical & Petrochemical – Lowering emissions while maintaining critical process reliability.
• Pulp & Paper – Reducing fuel costs and enhancing steam production efficiency.
• Institutional & Commercial Facilities – Improving boiler performance for hospitals, schools, and government facilities.

Each project is designed to meet the specific needs of the operation — from small-scale upgrades to large, multi-burner industrial retrofits.

Combustion Controls: The Key to Modern Efficiency

Modern burner systems rely heavily on advanced control technologies to maintain consistent combustion conditions. Bacon Engineering specializes in integrating these systems, including:

• Parallel Positioning Systems – Replacing traditional mechanical linkages with electronic actuators for precise fuel-air control.
• Oxygen Trim Controls – Continuously adjusting air input based on real-time oxygen readings for optimal combustion.
• Variable Frequency Drives (VFDs) – Regulating fan and blower speeds to reduce electrical consumption.
• SCADA & Remote Monitoring – Allowing plant operators to monitor combustion data from anywhere, improving responsiveness and system visibility.

The combination of a high-efficiency burner and a state-of-the-art control system creates a balanced, efficient, and safe combustion process — delivering maximum return on investment.

Sustainability and Environmental Impact

Burner retrofits are not only about performance and savings — they are also a crucial step toward environmental responsibility. By improving combustion efficiency, facilities can significantly reduce their carbon footprint.

Lower NOx and CO emissions contribute to better air quality and compliance with EPA and local air district standards. Additionally, many retrofit projects qualify for energy efficiency incentives or carbon reduction programs, further enhancing financial returns.

For companies striving toward sustainability goals, partnering with Bacon Engineering provides a practical pathway to greener, cleaner operations without the cost of full equipment replacement.

Why Choose Bacon Engineering

For over [insert years if known], Bacon Engineering has been a trusted partner in combustion system design, boiler control integration, and burner retrofit solutions. Our team brings together a unique blend of engineering expertise, field experience, and commitment to innovation.

We focus on long-term performance, not quick fixes — ensuring every retrofit is optimized for efficiency, compliance, and operational reliability. From consultation through commissioning, Bacon Engineering stands behind every project with responsive service and technical excellence.

Conclusion

A burner retrofit is more than just an equipment upgrade — it’s a strategic investment in your facility’s future. By modernizing combustion systems, businesses can reduce costs, improve reliability, and demonstrate environmental leadership.

With Bacon Engineering as your partner, you gain access to the latest in burner technology and control innovation — backed by decades of experience in combustion system integration. Whether your goal is to meet new emissions standards, improve efficiency, or extend the life of existing equipment, our customized retrofit solutions deliver proven results.

Enhance your efficiency. Reduce your emissions. Extend your system life — with Bacon Engineering’s burner retrofit solutions.