Heating is often the single largest winter utility expense for commercial and industrial buildings in Southeast Wisconsin. The good news: many facilities can reduce fuel use meaningfully without new equipment, simply by tuning what they already have and using their building automation system more effectively.
At BREDAN Mechanical Systems, our service and controls teams help facilities across Waukesha and Milwaukee find these savings every winter. Here are the strategies that make the biggest difference.
Boiler Plant Optimization
Combustion Tuning
A boiler running with too much excess air sends heat up the stack. Annual combustion analysis and burner adjustment keep air-to-fuel ratios where they should be across the firing range.
Outdoor Reset
Outdoor reset adjusts supply water temperature based on outdoor conditions. On a 35°F day, the building does not need the same water temperature it needs at -10°F. Proper reset curves reduce cycling, lower losses, and allow condensing boilers to actually condense.
Lead/Lag and Staging
In multi-boiler plants, sequencing matters. Running several boilers at low fire is often more efficient for condensing equipment, while older non-condensing boilers may perform best with fewer units at higher fire. Your control strategy should match your equipment.
Water-Side Maintenance
Scale and sludge reduce heat transfer. Maintaining water treatment and flushing strainers keeps the plant running at design efficiency.
Building Automation Strategies
Optimized Start/Stop
Instead of starting equipment at a fixed time, optimal start calculates when to begin heating so the building reaches setpoint right at occupancy – no earlier.
Smart Setbacks
Unoccupied setbacks save energy, but setbacks that are too deep can require long, high-demand recovery periods. The right setback balances savings, recovery time, and freeze protection for perimeter spaces.
Ventilation Control
Heating outdoor air is expensive in a Wisconsin winter. Demand-controlled ventilation using CO2 sensors reduces outdoor air when spaces are lightly occupied, while still meeting ventilation requirements.
Economizer Verification
An economizer stuck open in January can bring in large volumes of frigid air and drive up heating costs significantly. Regular verification of damper operation is one of the simplest savings measures available.
Trend Review
BAS trend data shows equipment short cycling, simultaneous heating and cooling, and schedules that no longer match building use. A periodic review often uncovers easy savings.
When Equipment Upgrades Make Sense
If your boilers are approaching the end of their service life, a planned replacement can deliver larger savings:
- High-efficiency condensing boilers paired with low-temperature reset strategies
- Modular boiler plants that match capacity to load
- Hybrid systems with heat pumps for shoulder seasons
- Variable speed pumping on hydronic distribution
Utility incentive programs may also help offset the cost of qualifying upgrades.
Heating Optimization Services in Southeast Wisconsin
BREDAN Mechanical Systems provides commercial boiler service, building automation programming, and HVAC system design for facilities throughout Waukesha, Milwaukee, Kenosha, Racine, Washington, Ozaukee, and Jefferson counties. Contact us to schedule a winter heating performance review of your boiler plant and controls.
