Client Overview
A large established food industry client required significant expansion to support its rapidly growing business. The company sought to convert a 200,000 sq ft warehouse into a high-capacity food packing and distribution hub capable of meeting strict environmental and operational standards.
Project Objectives
- Transform an existing warehouse into a temperature-controlled food processing and distribution facility.
- Maintain consistent 5 °C working temperatures throughout the large refrigeration space.
- Achieve a high airflow and air-change rate suitable for food-grade operations.
- Deliver a reliable, energy-efficient ventilation and cooling solution.
Engineering Solution
To meet these requirements, a comprehensive HVAC and air-distribution system was designed and installed. Key elements included:
Air Handling Units
- Installation of four large external air-handling units (AHUs).
- Each AHU equipped with:
- EC plug fans
- Thermal heat-recovery wheels
- High-level filtration
- Chilled-water cooling coils
Air Plenums & Distribution
- Custom-built, in-house-manufactured air plenums installed on site.
- Plenums linked to single header ducts all exceeding 2.0 m sq which extended into the roof void running over to the Food processing area.
Insulation & Condensation Control
- All ductwork insulated with 50 mm specialist insulation and vapour-sealed to prevent condensation associated with the low internal air temperatures.
Air Delivery System
- Header ducts routed across the ceiling and into the warehouse.
- Ducts penetrated through to connect with large fabric air socks, ensuring even air distribution and stable temperature across the entire workspace.
Outcome
The completed system successfully delivered:
- Consistent 5 °C controlled conditions
- Improved air quality and compliant air-change rates
- Energy-efficient operation through recovery wheels and EC fan technology
- A fully functional, food-grade packing and distribution environment tailored to the client’s expanding operations
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