Why Upgrading Burner Management Controls Matters:

The Hidden Power Behind Efficient Combustion

In the world of industrial heat generation, much of the attention falls on visible components like burners, boilers, and fuel supply systems. Yet behind every efficient, clean, and safe combustion system lies a vital but often overlooked element: the burner management control system. Whether operating in a hospital, food plant, refinery, or power station, keeping burner controls modern and fully optimised is key to ensuring safe operation, reducing emissions, and driving down operational costs.

Historically, burner systems were controlled mechanically. A burner’s fuel and air mix was managed by a series of metal linkages, cams, gears, and levers, adjusted manually by operators or service engineers. These setups were prone to wear, drift, and inconsistency, particularly as plant load conditions fluctuated. When set up well, they functioned adequately, but maintaining optimum efficiency required frequent recalibration and operator intervention.

These systems also lacked dynamic responsiveness. A sudden change in process demand or ambient conditions could easily knock the air/fuel ratio off balance, resulting in poor combustion, higher fuel use, and increased emissions. Even more critically, the reliance on mechanical parts posed a risk to safety, as worn linkages could result in unreliable purging, flame failures, or dangerous imbalances between fuel and air.

The advent of programmable logic controllers (PLCs) and digital actuators in the late 20th century marked the beginning of a control revolution. Today, electronic burner management systems (BMS) allow operators to move away from imprecise linkages and toward precise, repeatable digital control, improving every aspect of combustion performance.

One of the most important arguments for modernising burner controls is the potential for energy efficiency. Combustion is inherently a balancing act: too little air results in incomplete combustion and carbon monoxide formation; too much air wastes energy by cooling the flame and pushing heat up the flue.

Traditional systems often run with 10–20% excess air as a margin of safety, but this excess translates to wasted heat. Modern digital controls can reduce this margin to 5% or less, allowing for significant fuel savings.

To put this into context:

• On a boiler burning 1 million cubic metres of natural gas per year, even a 3% improvement in combustion efficiency can save over £20,000 annually, depending on gas prices.
• For multi-boiler sites or 24/7 process plants, these savings compound rapidly, often justifying the investment in control system upgrades every few years.

Modern systems also offer modulation control, allowing burners to match output more closely to demand. Older systems might cycle on and off frequently, known as “short cycling”, which consumes more fuel and places stress on components. By contrast, digital controls support smooth turndown, maintaining stable combustion at low firing rates and reducing wear on both the burner and the boiler.

At the heart of efficient combustion is accurate fuel-to-air ratio control. This is where modern burner management systems truly outperform their older counterparts. Digital systems use servo motors with precise positioning feedback, often to within 0.1°, to control damper and valve positions independently.

Additionally, many systems integrate oxygen trim control: a feedback loop that continuously adjusts the air supply based on the measured oxygen content in the flue gas. As environmental conditions (temperature, humidity, barometric pressure) and fuel characteristics change, the system adapts automatically to maintain optimal combustion conditions.

This adaptability is essential in:

• Facilities with variable fuel quality, such as waste-to-energy plants or those using biogas.
• Sites with multiple boilers, where combustion characteristics vary across units.
• Long-running industrial processes, where ambient conditions shift throughout the day and year.

The result? Stable combustion, reduced CO and NOx emissions, fewer shutdowns, and most importantly – less wasted fuel.

Another transformative aspect of modern burner controls is the operator interface. Traditional systems provided limited feedback – usually just indicator lights or analogue gauges. Faults often had to be diagnosed manually, sometimes requiring hours of investigation.

Modern systems like SAACKE SCanView or se@vis offer:

• Touchscreen interfaces with detailed system overviews.
• Real-time data logging of burner position, flue gas composition, fuel flow, temperature, and pressure.
• Remote monitoring and control, allowing plant managers or service providers to troubleshoot without attending site.

Operators gain a far deeper understanding of system performance and are empowered to act quickly when parameters drift out of range. For facilities with tight staffing or remote locations, these capabilities are invaluable.

The move toward data-driven maintenance is another major benefit of modern burner management systems. Sensors continuously collect data that can be used to identify trends and signal when components are degrading, long before they fail.

Examples include:

• Actuators that are taking longer to reach their position, suggesting wear.
• Trends in flue gas temperature indicating a dirty heat exchanger.
• Infrequent but recurring flame failures, pointing to ignition system fatigue.

Armed with this data, maintenance can be scheduled proactively, minimising unplanned downtime and preventing costly emergency callouts. Over time, this approach:

• Extends the lifespan of burner components.
• Reduces the total cost of ownership.
• Decreases plant downtime and production reliability.

Precise fuel/air ratio control is not just about efficiency – it’s a legal imperative.

Stricter environmental and safety standards are placing increasing pressure on combustion system owners. Environmental regulations such as the Medium Combustion Plant Directive (MCPD) impose strict limits on emissions from combustion systems. Non-compliance can lead to significant financial penalties and operational disruptions.

Modern BMS platforms are designed from the ground up to comply with these standards. Features include:

• Independent safety loops for fuel shutoff valves.
• Flame supervision with fail-safe logic.
• Automatic purge and ignition sequences.
• Event logs and alarm histories, essential for audits and investigations.

By contrast, older systems may no longer meet these requirements, even if they appear to function normally.

The Risks of Outdated Controls:

Traditional mechanical linkage systems lack the precision and real-time monitoring capabilities of modern digital controls. This can result in suboptimal combustion, leading to excessive emissions of pollutants like NOₓ and CO₂. Without accurate control, your facility may unknowingly breach emission limits, exposing you to regulatory action.

Regulatory Penalties Are Substantial:

Under the Greenhouse Gas Emissions Trading Scheme Order 2020, certain breaches can incur civil penalties of £20,000, with additional daily fines of £500 for continued non-compliance, up to a maximum of £45,000.

Beyond Financial Penalties:

Non-compliance can also lead to:

• Operational Shutdowns: Regulators may issue stop notices, halting operations until compliance is achieved.
• Reputational Damage: Environmental breaches can harm your company’s public image, affecting stakeholder trust.
• Increased Scrutiny: Repeated violations can result in more frequent inspections and stricter oversight.

Mitigating Risks:

Delaying upgrades to your burner management controls increases the risk of non-compliance and associated penalties. Investing in modern control systems not only safeguards your facility against regulatory action but also enhances operational efficiency and environmental performance.

Today’s industrial environments are becoming more connected. Control systems are expected not only to operate efficiently on their own, but also to communicate with building management systems, energy monitoring platforms, and even cloud-based AI analytics.

Modern burner controls such as SCanView and se@vis offer:

• Open communication protocols such as Modbus or TCP/IP over Ethernet.
• Integration into SCADA or BMS networks, enabling centralised control.
• Energy dashboard compatibility, supporting ESG and sustainability reporting.

These capabilities make it easier for businesses to manage energy use holistically, optimise across the entire plant, and report emissions performance transparently.

SAACKE has been at the forefront of digital combustion control for decades. Our se@vis and SCanView control platforms, offer a powerful and flexible burner management solution. With precision servo control, intuitive user interfaces, and full integration capability, these systems support everything from small commercial boilers to large-scale industrial burners.

 SCanView

• Cost effective, feature-packed solution for fired plant
• Targeted use for steam and hot water boilers
• Semi-automated safety test system (weekly evaporation test, safety limit, safety valve test, etc.)
• Option for remote monitoring and support (SAACKE SCanViewERS)
• Option for integrated boiler water level controls (SAACKE BWC)
• Option for combined or simultaneous firing of multiple fuels
• Option for use in hazardous area (ATEX)
• Suitable for use in (up to) a SIL 3 SIF

se@vis 4

• Feature-packed solution for complex fired plant
• Targeted use for Waste-to-Energy, process burners, incinerators, and complex boiler applications
• Option for combined and simultaneous firing of multiple fuels
• Option for use in hazardous area (ATEX)
• Suitable for use in (up to) a SIL 3 SIF

Our controls are designed not just to meet current standards, but to exceed them , offering a platform for predictive maintenance, remote diagnostics, and future system expansion. At SAACKE, we see controls not as accessories, but as core drivers of combustion performance , and we work closely with clients to ensure every system is configured for peak efficiency, safety, and compliance.

While it’s easy to focus on fuel types, burner designs, or boiler capacities, the true enabler of modern combustion performance is control. Outdated control systems not only waste energy, but also compromise safety, increase emissions, and limit operational insight.

Investing in up-to-date burner management controls offers:

• Lower fuel bills
• Better plant uptime
• Improved environmental compliance
• Increased operational visibility
• Enhanced safety for operators and assets

Whether you’re operating a single boiler or managing a large industrial energy centre, upgrading your burner controls is one of the most impactful steps you can take. With modern technology now offering powerful tools like servo control, oxygen trim, and predictive diagnostics, there has never been a better time to modernise.

If you haven’t reviewed your burner management system in over five years, now is the time to explore what a modern control platform can deliver – for your energy use, your emissions targets, and your peace of mind.

Upgrading from mechanical linkage to digital burner controls is a big leap in performance, but digital doesn’t mean done. Just because you’ve already installed a digital burner management system doesn’t mean it’s keeping up with modern requirements.

Technology evolves, and so do safety, compliance, and performance expectations…

Why Upgrade Your Digital Controls?

Even digital systems become obsolete over time. Manufacturers phase out legacy software and hardware, meaning:

• Spare parts become harder to source
• Support becomes limited or unavailable
• Cybersecurity risks increase with outdated platforms
• Compatibility with newer plant infrastructure suffers

An outdated control system can be just as risky as an old mechanical one, even if it’s still “working.” The difference is that a modern digital upgrade offers smarter diagnostics, tighter integration, and improved compliance tracking – all essential in today’s data-driven, low-carbon environment.

The Hidden Cost of Holding On

Keeping old digital systems might seem like a cost-saving decision, but in reality, it could be:

• Increasing your fuel use due to ageing sensors or inefficient logic
• Missing early warning signs of equipment stress or inefficiency
• Failing to meet current emissions monitoring expectations (especially under MCPD/LCPD)

Keeping Pace with Regulation and Efficiency Goals

Environmental and safety standards aren’t standing still and neither should your controls. Investing in current-generation digital systems ensures:

• Future-proofing against regulatory tightening
• Improved energy and carbon reporting for ESG or net-zero strategies
• Streamlined service and fault-finding with remote diagnostics

Don’t let “digital” give a false sense of security.
If your system’s more than 8–10 years old, it may already be behind — in features, efficiency, and compliance-readiness.

If you are interested to know more about controls upgrades, user training or how you can save money on the running of your plant, Contact our team today and we can arrange a more in-depth presentation for you, or organise  an initial free on-site consultation.