Slim solution

5 December 2001



The drycleaning industry has specific requirements of boilers. Derek Parish of Controlled Flame Boilers describes the changes that have taken place since the company started over 100 years ago


Controlled Flame Boilers has been producing commercial boilers since 1895. In the early 1920s it introduced its first boiler for the drycleaning industry designed to generate a fuel efficient source of high quality steam for these operations.The simple design and reliability of this single pass steam boiler soon led to it becoming market leader.

As with all products, there is a need to move on with the development of new and more innovative technology. While the original Controlled Flame Boilers device was operationally efficient and reliable, so much so that there are still a large number in daily operation, the need for regular replacement of the steel tubes added to overhead costs. Consequently, we decided to develop a product that would not only cut maintenance costs, but dramatically increase fuel efficiencies.

The introduction of the 4VT series in the 1990s provided a four-pass, vertical and tubeless design which satisfied all of these requirements. Unlike its predecessor, this boiler was able to operate on a choice of fuels, which included gas, oil and propane. It also provided a much larger range of outputs, each with auto-lighting and full safety features.

The 4VT boiler ensures efficient use of combustion gases by passing the generated heat over the water heating surfaces four times, via specially engineered ports and fins. Without the use of tubes and coils, its design enables this boiler to reach full output quickly and fuel efficiently. At the same time, by locating the burners at a convenient working height for adjustment and maintenance, costs for maintenance and servicing have been reduced.

A major difficulty for many drycleaners is the logistical problem of installing gas steam boilers within a cellar or basement and meeting the stringent requirements of the Health and Safety Regulations. Most of the available gas steam boilers were either too large to gain access into these areas or unable to meet emission limits. Consequently, proprietors were forced into choosing electrically powered boilers to satisfy their operational requirements. These were more expensive to operate and meant that the introduction of the compact CFB 4VT design was liberating for many drycleaning businesses. Virtually silent in operation, it was able to achieve savings of up to 75% on the annual fuel charge, thereby helping to considerably reduce overheads.

Long search

One drycleaner in London had spent more than 15 years' searching for a means of locating a gas-fired boiler within the basement service area. Having called in a number of boiler engineers the problems of providing a cost-effective solution, which could provide effective ventilation, seemed insurmountable. However, the compact design and technological advances of the 4VT gas-fired steam boiler satisfied its requirements perfectly.

As the boiler was located within an enclosed basement, we had to devise a system that would introduce fresh air into the basement via ducting and a small fan unit. Even without the use of a fan, the 4VT is able to run at approximately 20 to 40 parts per million carbon monoxide (CO). But with it, CO is virtually eliminated. The air management system draws fresh air from the outside through a separate air dilution system, so that fumes can be released as very low emission. This design innovation avoided the expensive and problematical installation of a five-storey flue and made it possible for the proprietor to enjoy the low operational costs offered by the 4VT.

While the 4VT is compact, there were still a large number of drycleaners that could not accommodate the boiler within their premises. By redesigning and altering the dimensions of the 4VT we were able to create a slimmer version for this market sector. This latest addition, introduced last year, was named "Slim Jim". It is so narrow that it can fit through standard doorways and be located in corners, thereby using limited space more effectively.

To make the controls, including blowdown, accessible for servicing and adjustment we have fitted these at the front of the boiler. The flueways are also located for ease of cleaning while a central air intake avoids dust and moisture from being drawn into the system. In applications where the combustion air is insufficient, we offer dedicated air intake as an option. This is fitted to the burner to avoid air being contaminated by chemicals used in drycleaning operations. It is particularly useful in below-ground applications.

Sketchley's drycleaners in Eastbourne is one business that has invested in a Slim Jim boiler because of its low running costs. An 8hp model has been installed to replace an elderly 35-year-old Controlled Flame Boilers' unit and is being used to generate a high quality source of steam for two Hoffman presses, an ironing board and a Böwe drycleaning machine. The success of this installation has led to a further 20 Slim Jims being installed throughout the Sketchley group.

Fast response

As the steam chamber is about 30% larger than most vertical boilers, the Slim Jim can respond and recover much more quickly to the peaks and troughs on demand. This capacity virtually eliminates the possibility of priming and avoids excessive amounts of moisture being carried over in the steam, thereby producing a drier source of steam, which enhances the finish on garments and textiles.

Sketchley has found a considerable difference in performance between its old boiler and the new technology. The old Controlled Flame Boilers' unit took up to three-quarters-of-an-hour to reach full pressure, whereas the Slim Jim achieves it in a third of the time. This means the new boiler is far more economical on both water and gas. The branch manager has also found that he doesn't need to get to work as early because the Slim Jim gets up to speed more quickly, and the quality of the steam achieves a good finish on all machines.

Controlled Flame Boilers is able to supply boiler systems as purpose-built plant rooms that can be roof mounted or located in a yard area. These are designed and constructed to fit the clients' available space and to save on-site installation time.



Say hello to Jayne and Tim

To complement the Slim Jim boiler range, Controlled Flame Boilers has introduced the Slim Jayne tank set and the Tiny Tim water softener. Both of these are designed to offer more compact solutions for the drycleaning industry. Designed to fit into corners, the Slim Jayne tank set combines feed tank, condense tank and blowdown tank into one unit to save floorspace. The top two sections are manufactured from heavy-gauge stainless steel to withstand the harsh treatment and corrosive condition to which these systems are normally exposed. Its design ensures that heat convection between the cold water feed and the hot returned condensate is greatly reduced, owing to an air seal that forms between the two sections. The Tiny Tim water softener has all the advantages of narrow dimensions combined with operational efficiencies. With reduced salt and water usage it achieves lower running costs and minimises limescale to improve boiler efficiency and extend product life. As it has an in-built memory it can monitor and record water usage and therefore establish the amount required on a day-to-day basis. This process ensures that the user’s needs are always met and that wastage is avoided.




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