COOL RESULTS FOR VDC GROUP

VDC Group, an independent UK market leader in optical disc manufacturer, had a problem at their distribution and warehouse centre. In summer the 50,000 sq. ft. mezzanine became uncomfortably hot with temperatures reaching up to 38°C. VDC Group required a cost effective way of providing cooling and reducing humidity levels.

Clean Air carried out a site survey and it was determined that four strategically placed evaporative coolers would enable cool fresh air to be introduced to the area. Galvanised ducting drops vertically from the roof and fresh, cool air is then distributed through ductwork and four-way plenums resulting in a comfortable working temperatures of 22°C. The cooling system can be controlled at the touch of a button using an Industrial Wall Control (IWC) which also provides comprehensive fault diagnostics.

Following the success of the Evaporative Cooling System Clean Air Group were then asked to install a further cooler in the company’s printing department.

“Before the evaporative coolers were installed, in peak summer we had every door and shutter open, but the temperatures were very uncomfortable”, says Joe Bennis, Group Manager,“The coolers have transformed our business. Now instead of agency staff refusing to work for VDC Group, they are now requesting to work for us and as the evaporative system introduces naturally cooled fresh air, the atmosphere is really invigorating”.

“Although the evaporative coolers have only been installed on the mezzanine floor, the cool air flows down to the ground floor to help reduce temperatures there as well”, said Joe Bennis. “The system is working very, very efficiently and is very economic to run.”

TECHNICUT COOLS DOWN WITH CLEAN AIR

By installing the latest evaporative cooling technology at its manufacturing facilities in Sheffield, Technicut have reduced summer temperatures in their machine shop from a sweltering 32°C plus to a comfortable 26°C.

Technicut Ltd, a UK market leader in the design, manufacture and supply of specialist rotary cutting tools, found evaporative cooling such a cost effective answer to its space cooling problems that a further three additional coolers were then installed into remaining bays.

Roof mounted evaporative coolers inject a constant flow of naturally cooled air, distributing it via strategically placed internal vents and providing cooling exactly where it is required. Programmable regulators control temperatures with four different control modes.

“Prior to the evaporative coolers being installed, we relied on opening doors and windows and using fans to create air movement”, says Peter Nield. “Despite this, temperatures were still unbearably hot and employees regularly complained. Since the coolers were installed by Clean Air we have seen a drop of between 6 to 8°C, which has drastically improved conditions.”

“Technicut has a policy of integrating health, safety and environmental considerations into all aspects of its business”, says Marie Wren, Managing Director of Clean Air Group. “Although Technicut’s primary concern was for the welfare of its employees, the energy saving costs of the evaporative system was a major factor in the company’s decision."

DORMER TOOLS GET SUMMER COOL

For Dormer Tools, one of the world’s largest producers of high-speed steel cutting tools, it all started with a visit to Clean Air Group’s stand at the MACH2004. Dormer Tools Managing Director, Terry Allison, requested a site survey be undertaken and it was calculated that 22 coolers would be needed to provide evaporative cooling throughout the 5,000 sqm production facility.

There are two main areas within the large production facility, one part dedicated to grinding machinery and the other to heat treatment. Despite the installation of roof vents and fresh air fans temperatures in the heat treatment vicinity, especially around furnaces, reached well in excess of 30°C in the summer.

After an initial trial of a single cooler proved successful 6 further coolers were installed to the heat treatment plant with internal vents strategically placed to inject fresh, cooled area to the hot spots. It is intended to phase in the remaining 15 coolers until the whole of the production facility is covered.

“The evaporative cooling system has reduced temperatures by around 8°C to 10°C in the heat treatment plant which has made a tremendous difference to our workforce”, said Martin Monaghan, Project Engineer. “Now, the rest of the workers are asking when their area can be fitted with the units”.

“Providing cooling for workers in industrial environments to improve productivity and reduce absenteeism from heat stress has previously been perceived as financially prohibitive”, said Marie Wren, Managing Director of Clean Air Group. “Now, however, many companies are turning to evaporative cooling as it provides a cost effective solution for cooling large areas”.

EVAPORATIVE COOLING IS THE ANSWER TO LOWERING TEMPERATURES AT WDF

An evaporative cooling system installed by Clean Air at a cost of less than £60K now provides World Duty Free Europe (WDF) with the economical and environmentally friendly solution it needs for their 88,000 sq. ft. National Distribution Centre (NDC). Temperatures at their warehouse complex used to soare in excess of 36°C, now they have been reduced to a comfortable ambient temperature of around 22°C.

The NDC, which employs 214 people, operates 24-7 and is located close to a residential area subject to strict planning restrictions. It has no windows to provide natural light or ventilation and access is limited to the goods-in/out entrance and fire doors. Excessively hot during the summer, the problem was even worse for employees using the mezzanine floor occupying half the building. A solution was urgently required. Air conditioning was dismissed as unviable option, and an air change system did not resolve problems sufficiently.

Following a comprehensive site survey Clean Air’s engineers recommended the solution which would solve the problems once and for all - evaporative cooling technology. Fresh air is continually drawn from outside, filtered and washed, and then pushed around the building providing sufficient cool air to overflow and prevent hot air entering. The constant flow of naturally cooled air avoids the potential for "sick building" syndrome (caused by constantly circulating air) and is highly practicable since doors and windows can be left open. It is both environmentally friendly and cost effective to run - consuming considerably less energy than conventional air conditioning systems.

Clean Air installation was quick and hassle free. Thirteen units were installed on the roof with internal vents strategically placed throughout the warehouse complex. Wall mounted climate control panels offering four different control modes allowed precise management of the temperature in different parts of the building.

As Mike Pincott, Head of Property & Logistic Development, World Duty Free Europe says the new evaporative cooling system "has proved to be extremely successful and has provided us with a very cost effective solution to our high temperature problems".

CLEAN AIR WINS HALF MILLION POUND CITY CONTRACT

Clean Air has been chosen by Ballymore Properties to install air conditioning to the premier apartments within their prestigious New Providence Wharf development. In addition to a complete new residential urban quarter, the development features Docklands' largest private health complex for which Clean Air will be designing and installing the appropriate heating, air conditioning and ventilation solutions.

Marie Wren, Managing Director, commented "This is an exciting project which pulls together all the skills across the Clean Air Group".

New Providence Wharf. Docklands' finest development.

"We required air conditioning, heating, ventilation and air filtration systems, installed to the highest standards, with the minimum fuss. We accepted no compromises and Clean Air delivered. This contractor excel in their business."
Ballymore Properties Ltd

CLEAN AIR REDUCES THE TEMPERATURE AT MARTIN BAKER

With summer temperatures on the factory floor in excess of 40C an urgent cooling solution was called for.

Previous cooling methods had proved ineffective and heat was having an an adverse effect on the workforce's morale, decreasing productivity and increasing downtime. Site Manager Graham Dumbleton investigated his options. What was required was a highly effective, cost effective (in terms of capital expenditure and running costs) solution. Clean Air had the answer; 15 evaporative cooling units with the coolers strategically placed to provide spot cooling at specific areas around the factory. The result? Evaporative cooling now means a comfortable ambient temperature of around 23C and staff morale is flying high.

EVAPORATIVE COOLING LOWERS TEMPERATURES AT LONDON TAXIS INTERNATIONAL WORKSHOP

High temperatures and poor air quality are no longer problems at London Taxis International (LTI) Coventry workshop. Evaporative cooling has provided the solution LTI, manufacturers of the famous ‘black cab’, were looking for. The installation has proved such a success that Clean Air has gone on to install more evaporative coolers to LTI’s offices as well.  



The problem area was a ‘curtained off’ 1170 square metre area of the workshop contained within a metal-framed building with a corrugated iron roof. Temperatures reached around 40°C in the summer which, when combined with the welding fumes, made for very uncomfortable and difficult working conditions for the 28 employees.

CLEAN AIR PROVIDES SPECTACULAR INDUSTRIAL COOLING FOR RODENSTOCK

Rodenstock is one of the world’s largest suppliers of spectacle frames and lenses. Its 52,000 square foot production facility is divided into six production departments. Three of these departments became unbearably hot in the summer which was affecting staff morale.

Following the successful trial of portable mobile evaporative coolers, it was decided that a permanent solution utilising the same technology was the way forward. Clean Air has now installed two evaporative coolers into each of the three production halls providing a cost-effective cooling system with dramatic effects. The 100 employees in these areas now enjoy a comfortable working environment as fresh cooled air is distributed via ductwork to air diffusers. Hot air is expelled and soaring temperatures are reduced. Wall climate control units offer four different modes for precise control of cooling. In timer mode this means units are turned on an hour before production begins at 6.00 a.m. and turned off when the factory closes at 2.00 a.m. In Auto mode the system monitors the temperature and automatically increases or decreases the fan speed to maintain comfort. Fan mode offers the simple choice of operating the system as a ventilator.

As Andy Cobbold says, evaporative cooling “is a first rate system for a number of reasons. It provides cooled fresh air as well as natural ventilation and in addition to being cost effective, quick and easy to install, and low maintenance, it is also environmentally friendly."

"Rodenstock’s management wanted to provide its employees with a better working environment", concluded Marie Wren, Managing Director of Clean Air Group. "Evaporative cooling provides effective industrial cooling and is a simple, safe and low cost solution for the cooling of people and processes."