Client & Project Overview
Gypsum Industries, founded in Kingscourt, Co. Cavan in 1936, is Ireland’s leading manufacturer of plaster, plasterboard, and drylining systems. Operating today as Gyproc Ireland and part of the Saint-Gobain Group, the company plays a central role in supplying the Irish construction sector with high-performance building materials. As an energy-intensive manufacturer, Gypsum Industries continues to explore opportunities to improve efficiency and reduce environmental impact across its production processes.
PEMCAS was engaged to assess the potential for heat recovery from the gypsum drying process at the Kingscourt facility. The objective was to determine whether waste heat generated during production could be captured and reused in a practical, reliable, and cost-effective way, without disrupting ongoing manufacturing operations.
The project began with detailed data gathering and analysis. PEMCAS collected energy performance data over an extended period and carried out feasibility studies on a range of heat recovery technologies. Energy modelling was used to evaluate each option, with outputs presented in clear, decision-ready formats covering capital cost, programme implications, technical risk, and projected energy savings. Based on this analysis, a preferred solution was selected in collaboration with the client.
PEMCAS then progressed the project through detailed design and delivery. This included mechanical, electrical (ATEX-rated), and structural design, alongside safe-works planning for installation in a live industrial environment. PEMCAS managed the tender process, oversaw construction and fit-out works on site, and supported the project through to completion and handover. The system was successfully commissioned, with operational performance confirming that the anticipated energy savings are being achieved.
Key Insights
This project demonstrates the value of taking a structured, evidence-based approach to energy efficiency in industrial settings. By investing time upfront in data collection and modelling, Gypsum Industries was able to make informed decisions grounded in real operational performance rather than assumptions.
The success of the project also highlights the importance of designing solutions that are tailored to the specific process and site conditions. The bespoke medium-temperature heat recovery system designed by PEMCAS captures waste heat from the drying process and uses it to preheat supply air feeding the gas-fired process heater—delivering tangible efficiency improvements without adding operational complexity. Practical engineering, applied with clarity and care, delivered measurable savings and long-term value for the client.
