Ventilation is one of the largest single energy consumers in industry. At the same time, it is also one of the most effective areas for achieving savings—when the efficiency of heat recovery (LTO) is at the right level. With properly sized and modern LTO systems, annual energy savings of 20–40% can be achieved, and in some cases even more.
But what determines LTO efficiency, and what kinds of solutions make these energy savings realistic?
LTO Efficiency in Industry – How to Save 20–40% Energy
Ventilation is one of the largest single energy consumers in industry. At the same time, it is also one of the most effective areas for achieving savings—when the efficiency of heat recovery (LTO) is at the right level. With properly sized and modern LTO systems, annual energy savings of 20–40% can be achieved, and in some cases even more.
But what determines LTO efficiency, and what kinds of solutions make these energy savings realistic?
What Does LTO Efficiency Mean?
LTO efficiency describes how much of the heat energy recovered from exhaust air can be transferred to supply air.
High efficiency = less heating energy, a smaller carbon footprint, and lower operating costs.
- Good efficiency: 60–75%
- Top-tier solutions: up to 80–90%
- Weak or outdated LTO: 20–40%
In many industrial facilities, the LTO system is original to the building and clearly undersized—or missing entirely.
Special Challenges for LTO in Industry
Industrial facilities differ from offices and residential buildings in many ways:
- Large air volumes
- High contamination load (dust, process residues)
- Limited space in mechanical rooms
- Varying temperatures and humidity levels
- Higher pressure differences and filtration requirements
For these reasons, more efficient, durable, and service-friendly solutions are required—especially when significant energy savings are the goal.
How Industry Achieves 20–40% Energy Savings with LTO
1. Upgrade to a High-Efficiency LTO Solution
- Rotary heat recovery → up to 70–80% efficiency
- Counterflow plate heat exchangers for large air volumes → 60–70%
- Separate heat exchangers for demanding process environments → 40–70%
In older units, LTO efficiency is often at the 20–40% level—upgrading to a modern solution can cut heating energy demand in half.
2. Proper Filtration – The Key to High Efficiency
A dirty heat recovery wheel or plate pack quickly loses performance.
- Correct filter class for industrial contaminants
3. Correct Sizing = Lower Electricity Consumption
Industrial ventilation units are often oversized or undersized, which increases energy consumption.
When properly dimensioned:
- Fan energy consumption decreases
- Pressure conditions improve
- The LTO system operates at maximum efficiency
Savings potential: 10–20%.
4. Outdoor Air Handling Unit – More Space and Better Efficiency
When the mechanical room is small, sufficient LTO surface area cannot be achieved.
With an outdoor-installed solution, space limitations are eliminated:
- More LTO surface area → higher efficiency
- Better service accessibility
- Insulated and weather-resistant construction
This is often the most cost-effective way to modernize industrial ventilation.
Real Savings: Fast Payback Time
Typical results in industrial facilities:
- 20–40% lower heating energy consumption
- Payback period of 1–4 years
- Reduced operating costs and maintenance needs
When air volumes are large, every percentage point represents thousands of euros per year.
Summary
Improving LTO efficiency in industry is one of the most effective ways to reduce energy consumption and CO₂ emissions. The greatest savings are achieved when you:
✔ Upgrade to a modern LTO system
✔ Improve filtration
✔ Re-dimension the units
✔ Utilize outdoor-installed solutions when space is limited
With the right choices, 20–40% energy savings are fully realistic—and often just the beginning.