Zircotec Ltd is seeking innovative engineering solutions to recover and reuse waste heat, optimise chilled water systems, and reduce overall energy consumption in its high-performance coating and heatshield manufacturing operations.
Successful applicants will be given the opportunity to pitch their solution to Zircotec Ltd. The winning applicant, as selected by the company, will then be eligible to apply for £25,000 grant funding to kickstart the development of the proposed solution through a 3-month project. Selected solutions will be piloted in Zircotec’s live manufacturing environment, with potential for commercial adoption and R&D collaboration.


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Zircotec Ltd is a UK-based leader in high-performance ceramic thermal barrier coatings and fabricated heatshield systems, serving automotive, motorsport, aerospace, and industrial sectors.
Our manufacturing processes use energy-intensive plasma spraying and fabrication equipment, which involves the use of multiple water chiller systems for process cooling, and compressed air systems for a range of activities. Heat generated in compressors and chillers is currently dumped to the environment and not utilised even during winter months, while chilled water provision is fragmented across multiple units. This creates inefficiencies, increases costs, and misses opportunities to use recovered energy. Furthermore, the chillers are being used to take heat away from process water flows that are initially relatively warm, and where heat could potentially be shed more efficiently and potentially reused via a water/air heat exchanger.
Zircotec is ideally looking for a solution that combines these different needs to improve overall energy efficiency of their operations.
</div>

Background

Zircotec is seeking a practical, scalable solution to optimise energy efficiency by better use and management of heat in its operations. This includes:
<ul>
<li>Capture hot air from compressor heat recovery systems.</li>
<li>Recover heat from chiller radiators for secondary use.</li>
<li>Consolidate chiller capacity into a single chilled water reservoir.</li>
<li>Reduce chiller usage through the use of water/air heat exchangers.</li>
<li>Utilise low grade heat from the above for space heating within our factory and/or offices.</li>
</ul>
Solutions are preferred that address most, if not all of these aspects ideally by combining requirements into a single solution.
The proposed solution must integrate with existing facilities, operate reliably in an industrial environment, and maintain the required cooling and coating performance to allow throughput and quality to be maintained.
This iX is in the Foundation Industries and supply chain challenges group, therefore, the solution provider will be eligible to apply for &pound;25,000 to develop the proposed solution towards meeting this challenge. The funding will cover a 3-month project, the details of which will need to be refined with Zircotec. It is envisaged that this 3-month project should deliver a complete system design, energy modelling to quantify potential savings and implementation roadmap to show how the solution will be integrated into live operations.

The Challenge

The solution must / should:
<ul>
<li>Integrate into existing facilities with minimal disruption.</li>
<li>Operate at industrial scale, compatible with coating and fabrication workflows.</li>
</ul>
Support the consolidation of chiller capacity while maintaining required cooling performance.

Functional Requirements

The solution must/should:
<ul>
<li>Enable measurable energy savings (electric and gas).</li>
<li>Provide clear and safe methods for heat recovery and redistribution.</li>
<li>Be robust, safe, and compliant with relevant regulations.</li>
</ul>
Equipment specification:
Chiller details:
<ul>
<li class="Normal1">Chiller Type: Air-cooled process chiller (outdoor)</li>
<li class="Normal1">Cooling Capacity: 15 kW (60 Hz) / ~51,182 BTU</li>
<li class="Normal1">Required Air Flow: 20,000 m&sup3;/h (~11,772 CFM)</li>
<li class="Normal1">Voltage: 460 V / 3-Phase / 60 Hz</li>
<li class="Normal1">Flow Rate: ~31.7 gpm (&asymp; 120 lpm)</li>
<li class="Normal1">Pressure: 3 bar (43.5 psi) or up to 5 bar</li>
<li class="Normal1">Water Reservoir Volume: 27 L (&asymp; 7.1 US gal)</li>
</ul>
*** We have 5 in use in the factory
&nbsp;
Compressor details:
<ul>
<li class="Normal1">Compressor Type: Fixed-speed, oil-flooded rotary screw (air-cooled)</li>
<li class="Normal1">Drive Motor Power: 45 kW (~60 HP)</li>
<li class="Normal1">Nominal Pressure: ~13 bar (&asymp; 190 psi)</li>
<li class="Normal1">Air Delivery (FAD) : ~216 ACFM / 6.1 m&sup3;/min at 13 bar</li>
<li class="Normal1">Noise Level: ~71 dB(A) @ 70% load</li>
<li class="Normal1">Weight: ~974 kg (~2,147 lb)</li>
<li class="Normal1">Dimensions (L &times; W &times; H) : ~1,722 &times; 920 &times; 1,659 mm (~68 &times; 36 &times; 65 in)</li>
</ul>
*** We have 2 of these in the factory

Technical Requirements

The solution must/should:
<ul>
<li>Operate reliably in industrial environments with high heat, particulates, and continuous-duty equipment.</li>
<li>Meet relevant health, safety, and environmental regulations.</li>
</ul>

Operating Conditions

The solution must/should not:
<ul>
<li>Require complete replacement of core manufacturing infrastructure with no retrofit pathway.</li>
<li>Reduce coating or performance.</li>
</ul>

Out of Scope

There is no fixed maximum budget for this project. However, proposed solutions should demonstrate a clear and justifiable return on investment, ideally achieving payback within 2-3 years based on projected energy cost savings. Costs should be proportionate to the scale of savings and environmental benefits, and competitive against comparable market solutions.

Cost Requirement

Successful applicants will be given the opportunity to pitch their solution to Zircotec Ltd. The winning applicant, as selected by the company, will then be eligible to apply for &pound;25,000 grant funding to kickstart the development of the proposed solution through a 3-month project. The selected solution may be piloted in Zircotec&rsquo;s live manufacturing environment, with potential for commercial adoption and R&amp;D collaboration.
Successful applicants will:
<ul>
<li>Pilot their solution in Zircotec&rsquo;s live production environment.</li>
<li>Receive technical support, process data, and performance benchmarking.</li>
<li>Be considered for commercial adoption and future collaborations.</li>
<li>Access wider markets in automotive, aerospace, and industrial thermal management.</li>
</ul>
The benefits package for a successful applicant may also include:
<ul>
<li>Support from Innovate UK Business Connect</li>
<li>Support in the development of a prototype or pilot</li>
<li>Technical support</li>
<li>Invitation to attend or present at Innovate UK Business Connect events</li>
<li>A potential business collaboration</li>
<li>Investor introductions (if investment is required)</li>
<li>Support if any Innovate or similar competitions are relevant.</li>
</ul>

Rewards & Market Opportunity

<ul>
<li>Challenge launch: 20th August 2025</li>
<li>Deadline for applications: 17th September 2025</li>
<li>Selection and notification of finalists: 10th October 2025</li>
<li>Pitch Day: 14th October 2025</li>
<li>Confirm selected solution provider: 22nd October 2025</li>
<li>Submission to Innovation Funding Service (IFS): 5th November 2025</li>
<li>Project length: 3 months, completion by 31st March 2026</li>
</ul>

Timescales

This iX is in the Foundation Industries and supply chains challenges. Due to the nature of this challenge and the funding support available, there are the following eligibility criteria:
<ul>
<li class="Normal1">Entrants to this competition must be a UK registered business.</li>
<li class="Normal1">Entrants can only apply to one of the Foundation Industries and supply chains challenges.</li>
</ul>

Eligibility

The application form for this challenge will require applicants to provide company information and answer 3 questions - Idea Summary, Technology Readiness and Intellectual Property &ndash; each with a limit of 300 words.
Additionally, the following documents must be attached for your application to be considered: 
<ul>
<li>Project plan</li>
<li>Project costings &ndash; only eligible costs will be funded, please read the <a href="https://www.ukri.org/councils/innovate-uk/guidance-for-applicants/costs-we-fund/costs-guidance-for-non-academic-organisations/">Innovate UK Costs guidance</a> for further information.</li>
</ul>
Your project must:
<ul>
<li>Have a grant funding request up to &pound;25,000 (eligible costs only, see above)</li>
<li>Start on 1st January 2026 and complete by 31st March 2026</li>
<li>Carry out its project work in the UK</li>
<li>Intend to exploit the results from or in the UK</li>
</ul>
Applications will be assessed on:
<ul>
<li class="Normal1">Relevance to the defined challenge</li>
<li class="Normal1">Benefit of implementation</li>
<li class="Normal1">Feasibility/economic viability</li>
<li class="Normal1">Innovative nature</li>
<li class="Normal1">Ability to launch in line with expected timescales</li>
<li class="Normal1">Credibility of applicant company</li>
<li class="Normal1">Coherence of the proposed business model</li>
<li class="Normal1">Development potential</li>
<li class="Normal1">Maturity of the solution</li>
<li class="Normal1">Suitability for the intended geographic market</li>
</ul>
If selected through this competition, you will be invited to apply for &pound;25,000 grant funding through the Innovation Funding Service (IFS). Applicants will need to upload the following documents to IFS once notified:
<ul>
<li>Project plan</li>
<li>Project costing</li>
<li>Minimal Financial Assistance (and de minimis where applicable) declaration (details can be found <a href="https://www.ukri.org/councils/innovate-uk/guidance-for-applicants/general-guidance/funding-rules/">here</a>)</li>
</ul>
Minimal Financial Assistance:
Grant funding in this competition is awarded as Minimal Financial assistance (MFA). This allows public bodies to award up to &pound;315,000 to an enterprise in a 3-year rolling financial period. If your application is successful and you are invited to apply for grant funding you will be asked to declare previous funding received by you. This will form part of the financial checks ahead of Innovate UK making a formal grant offer.

Assessment Criteria

Existing background IP associated with a potential solution will remain with Solution Provider(s). Where any new IP generation is envisaged, it will be subject to the mutual IP agreement of the solution provider(s) and challenge holder.
Any commercial deployment of a transferred solution or newly developed solution, through licensing, joint venture, partnership, or direct investment, will be subject to the commercial agreement between the solution provider(s) and challenge holder.
Where necessary, a non-disclosure agreement (NDA) may be signed to uphold confidentiality in the engagement between the solution provider(s) and challenge holder. (This would be expected to be after company selection, it is suggested that details of IP should not be disclosed, focus on the outcomes of the technology proposed).
Innovate UK and Innovate UK Business Connect do not take any share of IP ownership or enter commercial ventures through the iX programme.

IP & Potential Commercial Route

We recommend that you complete the application form in Google Chrome as other browsers may have compatibility issues. The application form does not need to be completed in one session and can be saved for future edits. Please ensure that you toggle &ldquo;Stage Complete&rdquo; for each section before submission. Note that you will no longer be able to edit your application once you have clicked &ldquo;Submit Idea&rdquo; at the bottom of the Summary page.

Application & Technical Guidance

By submitting an application to this Innovation Exchange (iX) challenge, you acknowledge and agree that the information you provide will be shared with Innovate UK Business Connect and the challenge holder for the purposes of assessment and selection. All information submitted will be handled in confidence and shared only with those involved in the assessment and selection process under appropriate confidentiality expectations.
Please consider the level of detail you share in your submission to ensure it aligns with your own internal confidentiality or disclosure policies.
A selected panel of assessors will review and score your application. The panel of assessors will meet and agree a consensus score. Successful solutions will be selected by the challenge holder. Success will be based upon total consensus scores, a portfolio approach and capacity within the challenge holder&rsquo;s organisation to carry out the projects.
For more information on how Innovate UK Business Connect handles personal data, please refer to our&nbsp;<a href="https://iuk-business-connect.org.uk/privacy-policy/" target="_new">Privacy Policy</a>.

Heat recovery and process efficiency optimisation in advanced plasma coating manufacturing

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This challenge is brought to you by:

Heat recovery and process efficiency optimisation in advanced plasma coating manufacturing