ICI CALDAIE – 50 YEARS OF HISTORY
ICI CALDAIE is a company with over 50 years of history and experience in energy management and heat production.
It was established in 1958 as a manufacturing company for the production of steel boilers with a high content of water for industrial processes. This is a sector in which it currently holds a worldwide leadership position by providing medium and high power generators for the production of high efficiency energy in the residential and industrial sectors.
Experience gained over the years in the industry, has allowed the company to transfer the know-how in the design and manufacture of industrial steam boilers to that of boilers for residential and commercial markets, with particular specialization in the construction of centralized systems.
Armed with this rare competence, ICI CALDAIE decided to focus on the international market, undertaking the process that led to the attainment of the international certification ISO 9001/94 and ISO 9002 in 2003 and established itself as a leading company in the international arena.
The concept of “high-technology heat” that has always guided the company, has now started to materialize with the management of heat generation systems and a new philosophy that puts customer satisfaction at the centre of the company. In this regard, ICI CALDAIE combines the supply of high quality products and innovation with the best service, accompanying the Client in the choice of the most suitable system for the maintenance, management and control of the system, guaranteeing the best performance and highest energy savings during use.
It is a time of great innovation for ICI CALDAIE which has enriched its product range by introducing satellite modules able to make the user autonomous and at the same time allow significant savings in terms of efficiency compared to traditional boilers.
Market entry of new products and services is combined with another challenge, the design and development of hardware and software for intelligent system management. In 2009, eterm™ was created, an electronic management system for maximum efficiency and responsible use of energy in heat generating systems, including integrated systems.
Today ICI CALDAIE is a benchmark for companies operating in the sector of steam generators for industrial processes and heating. The pioneering and innovative spirit that distinguishes it, still pushes the company to invest in the research and development of projects that aim at creating new energy systems with low environmental impact, exploring new applications, new technologies and alternative energy sources. Among the latter, great resources are being invested in heat production from hydrogen for the residential market, with technology that can enable multifamily units to be self-sufficient in terms of energy production, reduce emissions to zero and sell the excess energy on the network.
“We create value by increasing efficiency and reducing emissions”
R&D
The company’s pioneering and innovative spirit has led it to invest heavily in the research and development of projects for new energy systems with low environmental impact, to explore new applications, new technologies with low emissions and to work closely with top universities to develop ambitious and highly innovative research projects. In addition to the solid and continuous collaboration with universities, ICI Caldaie has strategic partnerships with trade associations, producers and complementary companies, valuable alliances for the development of new, highly innovative, successful, large-scale research projects, with the conviction that there is no greater force than that generated by a group of heterogeneous members working for the same goal.
commercial range
In the commercial 
market, condensing boilers are the most efficient and advanced combustion technology for space heating. The operation is based on the recovery of the latent heat of the flue gases that are made to condense through the heat exchange surfaces. In this way it is possible to achieve very high output up to 109%, drastically reducing emissions.
The equipment can be integrated with the eterm® system for its management and includes: online alarm verification with targeted and timely interventions on system problems already diagnosed, alignment of digital and analogue data for accuracy certified by the correct value of individual consumption, temperature control via web or smartphone for every unit, meter reading systems with graphs to monitor progress and compare with the outdoor temperature or average condominium temperature, delivery of the energy balance for the entire building and breakdown by individual unit.
The ICI CALDAIE range for the commercial market includes:
⦁ Modular and base condensing boilers ranging from 32 to 3000 kW;
⦁ Steel base boilers ranging from 22 to 3500 kW (flame inversion or 3 flue passes);
⦁ Solar installations;
⦁ Boilers;
⦁ Circulation unit;
⦁ Control panels;
⦁ Metering modules;
⦁ Services to manage and optimise heating systems by remote control.
Industrial range
In the industrial market, the products offered vary in scale and range from steam boilers complete with burner and electronic control to turnkey heating plants, always giving priority to solutions with high energy efficiency.
Over the past few years, all ICI CALDAIE’s efforts have been aimed at pursuing a strategy of reducing pollutant emissions and consumption.
The design, construction and choice of accessories for ICI boilers are such as to provide the user with operational reliability and absolute safety with the best possible performance while respecting the environment.
With this view, special projects have been completed for the supply of elements designed for specific client needs: special projects for transportable central heating plants, water-tube boilers, heat exchangers for flue gas from biomass.
The ICI CALDAIE commercial offer for the industrial market includes:
⦁ Steam boilers ranging from 50 to 25,000 kg/h (high and low pressure, flame inversion or three flue passes);
⦁ Superheated water boilers ranging from 233 to 17,000 kW (flame inversion or three flue passes);
⦁ Diathermic oil heaters ranging from 116 to 9300 kW;
⦁ Heat generators ranging from 2500 to 20,000 kW (flame inversion or three flue passes);
⦁ Prefabricated central heating plant;
⦁ Global safety systems to avoid constant presence of the conductor;
⦁ Services to manage and optimise the operation of generators with remote control;
⦁ Services for installation and maintenance.
PRODUCTION CAPACITY
The production
plant of ICI CALDAIE is located in the province of Verona, at the headquarters of the company, covering more than 30,000 square meters. The equipment and machinery are the most advanced, specialized in mass production, in steel processing including that of special steel such as stainless steel with Titanium necessary for the production of condensing generators, and in the production of powerful individual generators on order.
Production is specialized in processing plasma cutting, robot welding, hot forming and processing of thick steel plate, shaping corrugated combustion chambers, all with the assistance of control systems such as welding X-rays, penetrating liquids and ultrasound.
These skills are combined with specialization in associated production capacity: laser or plasma cutting, punching, robot bending and laser welding in high volume.
The boilers manufactured are completely designed in-house by highly skilled engineers with the help of CAD stations and thermofluid dynamic algorithms, which are then validated in the Research and Development Laboratory where it is also possible to inspect high-power boilers.
Thanks to these capabilities, about 7,000 boilers for commercial use and 700 industrial boilers are distributed each year worldwide, figures which make the production facility the largest in Europe for the production of steel boilers, both for commercial and industrial use.
ENERGY EFFICIENCY
Energy efficiency, environmental Sustainability and Cost Savings are the key points of the new era of technologies which ICI Caldaie S.p.A. aims to use to expand its core business.
Making the Central Heating Plant of its clients more efficient and providing a higher yield in terms of productivity and cost savings related to reduced consumption of fuels used in production processes is the focus of ICI Caldaie, maintained with a strong will and success.
Through technical and economic verification of the plant operation and management costs incurred by its clients and through the preparation of a Global Analysis of Energy efficiency, ICI CALDAIE is able to identify potential areas needing quick intervention and solutions that can be offered to meet the objectives identified.
In a historic moment like the present, ICI Caldaie wants to bet on the future economy of the country starting with the manufacturing companies, by offering them a service of overall Energy Efficiency Management.
QUALITY
Strong competitiveness in th
e international market, the elimination of customs barriers and demand that is increasingly oriented to high quality standards, have led ICI CALDAIE to develop a new culture of quality, based on the belief that meeting the needs of the client and respect for stringent quality standards are prerequisites for the progress of companies.
In 1993, ICIM (Institute of Industrial Certification for Mechanics) certified the Quality Management System of ICI CALDAIE according to the Italian, European and international standard, UNI EN 29002 (IS0 9002); in June 2002, BVQI (Bureau Veritas Quality Insurance) awarded ISO 9001/94 to ICI CALDAIE and in April 2004, the ISO 9001/00 Vision was awarded.
All ICI CALDAIE models carry the CE mark according to the related standards. The high pressure boilers are built in accordance with the Pressure Equipment Directive (Directive for gas appliances and pressure vessels). The company also has multiple national certifications for export purposes to many countries that require very restrictive hydraulic and mechanical tests such as ASME “American Society for Mechanical Engineers” certificates.
The certifications awarded acknowledge the efforts made by ICI CALDAIE and inform the market that the methods adopted comply with international regulations to ensure the best quality standards.
In this context, the development of all new products in compliance with increasingly stringent European regulations for fuel consumption and emissions, is entrusted to a Research and Development laboratory equipped with modern tools to verify the reliability and performance of boilers.
Each product is designed by the Engineering department and equipped with modern networked CAD stations. The preparation of semi-finished products is done with laser cutters and CNC machines. The perfect welding of the elements is ensured by modern robots and each boiler is subjected to severe testing which certifies its reliability.
