Industrial and commercial operators are under intense pressure to reduce energy costs and decarbonise their processes. Heating systems are at the core of this challenge, especially in sectors that require precise and continuous thermal treatments.
From conventional heating to radiant technologies: the current scenario
For decades, many industrial facilities have relied on convective air heating, often with hot air generators or steam systems. These technologies heat the air volume, which in turn heats people, products and surfaces. In high-bay buildings or partially open environments, this approach is inherently inefficient: a significant share of thermal energy accumulates under the roof or disperses through openings and leakage.
This principle is particularly attractive in environments with high ceilings, frequent door openings, localised process needs, or where temperature stratification is a recurring problem.
Within radiant technologies, two main families are relevant for industrial use:
- Gas-powered radiant systems (infrared gas heaters, radiant tubes, high-intensity burners).
- Electric infrared systems (short, medium, or long-wave emitters, panels, and lamps).
Both families exploit infrared radiation, but they differ deeply in energy source, temperature levels, emission characteristics, and system integration within industrial processes. Understanding these differences is crucial to making informed decisions on energy savings and the total cost of ownership.
Gas-powered radiant heating vs. electric infrared: how the technologies work
Principles of gas-powered radiant heating
Gas-powered radiant systems use the combustion of natural gas or LPG to heat an emitter (plate, tube, ceramic surface or metal surface) to a high temperature. The glowing hot surface radiates energy in the infrared spectrum, which propagates through the air with limited losses and is absorbed by people, products and surfaces.
In high-temperature radiant systems, the surface temperature of the emitter can exceed 800–900 °C, with radiant efficiencies that can reach and exceed 60–70% of the input energy under correct operating conditions, according to data published by several European industrial heating associations. The remaining fraction is lost primarily through flue gases, but can be partially recovered in modern designs.
In industrial thermal treatments, high-temperature radiant heaters are often used to:
- Preheat or dry components before coating, painting or bonding processes.
- Promote curing of coatings, resins or composites.
- Execute localised heating on specific zones of a product or continuous line.
Principles of electric infrared systems
Electric infrared systems convert electrical energy into heat within a resistive element, which then radiates in the infrared spectrum. Depending on the type of emitter, different wavelengths and surface temperatures are obtained:
Short-wave and fast medium-wave: very high surface temperatures (up to and above 2,000 °C for the filament), intense radiation and quick response times.
Medium and long-wave: lower surface temperatures, more diffuse radiation, better suited for some materials and comfort applications.
The nominal efficiency of converting electricity to radiant heat within the emitter can be high, often above 90%. However, the overall system efficiency must consider the primary energy used to generate electricity, transmission and distribution losses, and possible mismatches between the emission spectrum and the absorptivity of the treated materials.
Energy and cost comparison: what the data suggests
The debate on energy savings between gas-powered radiant heating and electric infrared is strongly influenced by energy prices, which have been particularly volatile in recent years. According to several analyses by European energy agencies in 2022–2024, industrial electricity prices have increased significantly in many countries, sometimes reaching values two to three times higher (in terms of cost per kWh) than natural gas on an equivalent energy basis, although with strong national differences.
To understand the economic implications, it is useful to reason in terms of:
Final energy cost per delivered useful kWh (i.e. the energy effectively absorbed by the product or environment to be heated).
System efficiency and controllability.
Matching between emission characteristics and process requirements.
Primary energy and system efficiency
When electricity is produced mainly from thermal power plants, the overall conversion efficiency from primary energy to electrical kWh at the user’s meter can be in the order of 35–45%, considering production and grid losses, according to data from international energy agencies. In contrast, natural gas used directly on site in high-efficiency industrial equipment can reach global efficiencies of 80–90% between combustion and utilisation.
Although electric infrared heaters have high local conversion efficiency, the primary energy cost per useful kWh can be higher than that of gas-powered systems, especially in countries where electricity is still largely generated from fossil sources and where industrial electricity tariffs include significant grid and system charges.
For industrial users, this often translates into a marked difference in energy cost: even if the radiant efficiency of an electric infrared emitter is slightly higher than that of a gas-powered emitter, the cost per useful kWh delivered to the product or environment can be lower for gas, due to the more favourable cost of gas per unit of primary energy.
Operating cost scenarios
While numbers vary by country and by contractual situation with suppliers, industrial comparative studies conducted between 2021 and 2023 in several European markets highlight that, under typical tariff structures, the cost per MWh of useful heat supplied by gas-powered radiant systems can be 20–40% lower than for electric infrared systems used for similar applications, especially where gas prices remain relatively more competitive than electricity.
Furthermore, gas-powered systems designed for high-temperature radiation can significantly reduce heating times in specific thermal treatments. This can translate into shorter cycle times, higher line productivity and, in some cases, the possibility of lowering overall process temperatures while achieving the same results, thanks to more concentrated and controllable heat fluxes.
Why high-temperature radiant heaters matter in industrial thermal treatments
Not all radiant systems are equal, particularly when industrial processes require specific temperature profiles, fast heating ramps or localised treatment on complex geometries. High-temperature gas-fired systems are designed precisely to meet these requirements.
Solutions such as Radiant High Temperature heaters for specific thermal treatments illustrate how the synergy between high surface temperature, optimised geometry and advanced control can provide a tailored answer to industrial needs where conventional heating or low-temperature radiant solutions would be insufficient or inefficient.
In practice, high-temperature gas radiant heaters allow:
High thermal flux densities on targeted zones, which are particularly useful in preheating, drying, and curing processes.
Rapid thermal response makes it possible to follow variable production profiles and reduce start-up and shutdown times.
Precision in process control, by regulating gas flow and modulating power in line with line speed, product geometry, and required treatment depth.
These features can result in energy savings at a system level, not just at the component level, because they enable process optimisation: less waste, fewer defects, fewer reworks, and shorter overall occupation of ovens or lines.
Risks and criticalities if no optimisation action is taken
Maintaining outdated or non-optimised heating systems in industrial and commercial environments entails several risks that go beyond the simple increase in energy bills.
First, there is a clear competitive risk. According to energy performance studies carried out in the manufacturing sector, energy can account for between 5% and 20% of total production costs, with even higher percentages in thermo-intensive processes. Any structural inefficiency, including in heating, erodes margins and reduces pricing flexibility.
Second, there is a regulatory and reputational risk. Many countries are introducing stricter requirements on energy efficiency in buildings and industrial processes, alongside obligations for energy auditing in larger enterprises and ESG disclosures for listed or larger companies. Failing to improve the performance of energy-intensive equipment can have implications in compliance reporting, access to incentives and the perception of the company’s environmental responsibility.
Third, there is a technical and operational risk. Systems that are poorly suited to the process can generate non-uniform treatments, defects in coatings, incomplete curing and quality issues that translate into scrap or rework. In fields such as automotive, aerospace or high-specification manufacturing, such defects are not merely inconvenient but can be unacceptable from a safety or contractual standpoint.
Opportunities and advantages of optimised gas-powered radiant heating
Conversely, investing in modern gas-powered radiant systems, especially in high-temperature configurations designed for industrial treatments, can unlock several tangible opportunities.
Reduction in energy bills and carbon footprint
Where natural gas prices remain structurally more competitive than electricity, properly designed gas radiant systems can reduce the cost of heat per unit of product. Combined with advanced controls (zoning, modulation, integration with process parameters), these systems can deliver further savings by limiting heat to where and when it is necessary.
From a carbon perspective, the balance is more nuanced. If electricity is generated primarily from fossil sources, using gas directly on site may result in lower CO₂ emissions per useful kWh of heat delivered. For this reason, energy managers should regularly update their analyses based on national generation mixes projections and long-term decarbonisation strategies.
Process quality and productivity
High-temperature radiant solutions offer process benefits that go beyond pure energy savings. The ability to apply intense and localised heat where needed can improve drying, curing, or preheating uniformity, leading to higher product quality and fewer non-conformities. In continuous production lines, a well-designed high-temperature radiant module can reduce residence times in ovens or tunnels, freeing capacity and enabling higher throughput without extensive structural modifications.
Flexibility and integration
Modern gas radiant systems can be integrated with building management systems and industrial control architectures. Digital controls, variable modulation and feedback systems allow a level of precision and dynamic adaptation that aligns well with modern production paradigms such as just-in-time manufacturing and batch size reduction.
This flexibility supports incremental modernisation strategies: it is often possible to retrofit specific zones or process stages with high-temperature gas radiant modules, without having to overhaul the entire heating infrastructure.
Regulatory and policy aspects to consider
Energy and environmental regulations significantly influence the choice between gas-powered and electric heating systems.
Large enterprises are often required to conduct energy audits and identify cost-effective energy-saving measures. Upgrading inefficient heating systems, including switches from convective to radiant technologies or optimisation of existing radiant equipment, frequently emerges as a recommended measure in these audits.
Second, many jurisdictions offer incentives or tax benefits for investments in high-efficiency equipment, including heating technologies that reduce energy consumption per unit of output or per square meter heated. Even where the incentive schemes are technology-neutral, high-temperature gas radiant systems can qualify if they deliver documented energy savings compared to baseline solutions.
Third, climate policies are progressively oriented towards reduction of greenhouse gas emissions. Some countries are introducing or strengthening carbon pricing mechanisms (either carbon taxes or emission trading systems) that directly affect the cost of using fossil fuels. Gas-fired systems may thus face rising operating costs over the medium to long term, partially offsetting their current energy price advantage compared to electricity.
However, in parallel, electricity tariffs may also be impacted by decarbonisation costs and grid expansions, making the comparison dynamic rather than static.
How companies can approach the choice: a structured methodology
Choosing between gas-powered radiant heating and electric infrared systems for industrial or commercial applications.
A practical approach may include the following steps:
Mapping of thermal needs: clearly identify where, when and how heat is needed (ambient heating vs. process heating, continuous vs. batch, required temperatures, exposure times, sensitivity of materials).
Assessment of existing systems: evaluate the performance, efficiency, controllability and maintenance status of current heating technologies, including any chronic issues such as stratification, uneven treatments or high maintenance costs.
Process impact analysis: examine how each solution affects product quality, cycle times, operational flexibility and integration with existing lines and control systems.
Regulatory and incentive analysis: verify current and anticipated regulations, audit obligations, available incentives and potential financing opportunities for efficiency investments.
Risk and sensitivity analysis: test how the economic and environmental comparison changes under different scenarios (e.g. higher electricity share of renewables, significant gas price volatility, introduction of stricter emission rules).
Only by combining these perspectives can an enterprise determine whether modern gas-powered high-temperature radiant heaters represent the best choice relative to electric infrared systems for its specific context.
FAQ: common questions on gas-powered radiant heating and electric infrared
Are gas-powered radiant systems always more economical than electric infrared?
Not in every case. The economic advantage of gas-powered radiant systems depends on the relative prices of gas and electricity, the type of process, the utilisation profile and the efficiency of each system. In many industrial contexts where gas is competitively priced and used in high-efficiency equipment, gas radiant heating can offer lower operating costs per useful kWh of heat delivered. However, in regions with low-cost, low-carbon electricity, the balance can be different. A case-specific analysis is necessary.
Do gas-powered high-temperature radiant heaters increase CO₂ emissions compared to electric infrared?
The answer depends on the carbon intensity of the electricity mix and the overall system efficiency. If electricity is mostly generated from fossil fuels, direct use of gas on site in efficient radiant systems may result in comparable or even lower CO₂ emissions per useful kWh of heat. As the share of renewables in the grid increases, electric systems tend to improve their carbon performance over time.
Is it possible to combine gas-powered radiant heating with other technologies in a hybrid system?
Yes. Many industrial and commercial facilities adopt hybrid approaches, using gas-powered radiant systems for base load or high-intensity process heating. Hybrid systems can provide flexibility to respond to changes in energy prices, regulatory requirements and production patterns.
Conclusion: Strategic use of gas-powered radiant heating in a changing energy landscape
In the current energy and regulatory context, gas-powered radiant heating – and in particular high-temperature solutions tailored to industrial thermal treatments – represents a powerful tool for enterprises striving to reduce energy costs and improve process quality. While electric infrared systems offer advantages in terms of ease of installation and in some specific applications, they are often penalised by the higher cost of electricity and, in certain contexts, by the primary energy balance.
The most effective strategy does not consist in choosing a technology based on generic assumptions, but in conducting rigorous technical and economic analyses that take into account the characteristics of the process, the structure of energy tariffs, regulatory trajectories and the long-term evolution of the energy mix. Companies that approach the issue in a structured way can transform the optimisation of heating systems from a mere cost-control exercise into a strategic lever for competitiveness, quality and sustainability.
