Nexterra Systems and Helical Works: Forging a New Partnership
Global Energy Experts with an Innovative Biomass Plant at the University of British Columbia.
The Client
Founded in Vancouver in 2003, Nexterra Systems Corp is a global leader in gasification systems that produce clean, renewable heat and power. Their mission is to make the world cleaner and more sustainable by creating valuable energy from local, renewable waste. After establishing seven commercial plants in North America, Nexterra has now expanded into the United Kingdom with two new 10-megawatt biomass power plants.
The combined heat and power (CHP) system at the Vancouver campus of the University of British Columbia (UBC) is a partnership with the university and General Electric, which supplied the high-efficiency Jenbacher internal combustion engines for producing the clean, renewable electricity. The power plant is North America’s first commercial demonstration of a transformative system that combines Nexterra’s unique gasification and syngas conditioning technologies. The President of UBC, Dr. Stephen Toope, has referred to the site as a “living laboratory” where researchers, staff, students and partners collaborate on innovative energy solutions.
The Challenge
In the summer of 2024, the steel fabrication company that Nexterra had been using for years went out of business. According to Kelly O’Neill, Director of Nexterra Systems, they were desperate for help. “We had parts sitting in their shop, half-finished,” O’Neill said, “so I had to scramble to find another solution.”
Added to the challenge of sourcing another fabricator was the fact that Nexterra’s equipment was highly specialized and often required custom manufacturing. O’Neill was reasonably cautious about securing a new partner for their needs. “We do our own engineering for all of our equipment, all of the drawings and design,” he emphasized, “so we needed a manufacturer to build the parts according to our specifications and then follow through with installation.”
The Solution
It was not long before O’Neill discovered Helical Works and was able to arrange a meeting with General Manager, Paul Hiebert. “I told him what our business was all about, and what we needed,” said O’Neill, “and it seemed to us like Helical was a good fit.”
Initially, Helical Works finished the pieces that had been stalled with the previous fabricator. In the process, they discovered that even before that company had gone bankrupt, the fabricator was sourcing specialized parts from Helical Works to pass on to Nexterra. So, the relationship between Helical and Nexterra had been longer than first thought.
Very quickly, Helical was supplying Nexterra with two new double screw conveyors, two leveling screws, horizontal screws, ash conveyor screws, and a rebuild of a vertical screw. In fact, at the time of writing (in March 2025), there were four more new vertical feed screws being fabricated at the Helical shop.
“Since last summer, the work has been pretty much constant,” O’Neill said. “There hasn’t been hardly any time that we haven’t had something in Helical’s shop that they’re building for us.”
“Since last summer, the work has been pretty much constant,” O’Neill said. “There hasn’t been hardly any time that we haven’t had something in Helical’s shop that they’re building for us.”
At first, Helical’s products for Nexterra were for use at their UBC power plant, but very quickly they were also being supplied to another local gasification system at the Kruger Products paper mill in New Westminster, BC.
As well, the business between the two companies continues to grow as needs arise in Nexterra’s UK biomass plants. There is currently one horizontal feed screw that is being delivered to the UK, and several more helical products being manufactured in the shop that are also destined for those plants.
According to O’Neill, Helical has shown exemplary responsiveness and adaptability. “Some of our machinery is pretty unique,” he explained, “like our vertical screws that require a very specialized process for applying a hard surfacing coat to the product. The Production Manager at Helical, Nathan Gole, did the necessary research and picked up the process very quickly to deliver exactly what we needed.”
O’Neill also expressed appreciation for Helical’s commitment to collaboration. “At Nexterra, we have a strong quality control program in place,” he noted, “so we require extensive documentation for all our products. But Nathan always ensures that all the paperwork is completed as required, and that we receive detailed records and photos of the finished products from Helical.”
“At Nexterra, we have a strong quality control program in place,” he noted, “so we require extensive documentation for all our products.
But Nathan always ensures that all the paperwork is completed as required, and that we receive detailed records and photos of the finished products from Helical.”
The Outcome
In less than a year, Helical has forged a significant partnership of trust and collaboration with Nexterra Systems. According to O’Neill, the new working relationship has been seamless: “Their products are operating without any issues, and everything’s been pretty much on schedule,” he emphasized. “Whenever I’ve asked for an update on the progress, I always get an answer right away.”
Along with custom manufacturing, Helical Works has also provided field services to Nexterra, including installation, inspections, and general maintenance. According to Brian Dyck, Technical Sales Representative for Helical, their field crews have been onsite regularly at Nexterra’s local plants to assist with finetuning and ensuring that everything is operating as expected.
With a shared commitment to quality and innovation, Nexterra Systems and Helical Works are poised for success into the future.
Helical Works Co
2255 Townline Road
Abbotsford, British Columbia
Canada, V2T 6H1
Phone: 1-833-296-2234
Fax: info@helicalworksco.com