FACTORY, OFFICES AND SERVER ROOM, IT'S A COOL SOLUTION ALL ROUND FOR JOHN CRANE
The winners of the 2006 Queens Award for Enterprise, John Crane are a world leading company who provide engineered products and services to industries which include oil, gas, chemicals and pharmaceuticals. John Crane is a part of the global engineering business Smiths Group, who employ around 22,000 people in over 50 countries.
At the recommendation of an existing client, Hewland Engineering, Clean Air were asked to reduce the temperatures of their stores and machining areas. In just four weeks twelve Cool Breeze QAD230 units were fitted, alongside a pair of extract fans that compliment the existing passive roof ventilation units. Now staff enjoy a cool work environment and benefit from the natural fresh air that is continually introduced and circulated around the factory floor. Each Cool Breeze unit is individually controlled to provide different temperature zones between the areas.
The results proved so impressive that the factory became a more comfortable environment than the large open plan offices. These were being cooled using an old water chiller that supplied numerous indoor fan coils. Like many pre 2002/3 air conditioning units it used R22 as its refrigerant - an issue that needed to be addressed since virgin R22 is now prohibited for servicing or maintenance. Another problem was reliability - regular breakdowns meant high running and maintenance costs. Having visited another Clean Air installation at Scantech, John Crane was confident to accept Clean Air's recommendation to install an evaporative cooling solution for their offices. It was not long before four Cool Breeze QAD230 units had transformed the workplace. Cool, fresh air is now delivered through flexible spiral ducting that terminates with numerous grilles within the suspended ceiling in all areas of the office. The result is not just a comfortable working environment and contented staff, but also energy savings of up to 80% and low maintenance costs. Great news financially and an important contribution to meeting John Crane's environmental targets.
Clean Air has now turned their attention to their large server room, currently cooled by old air conditioning systems. A Cool Breeze evaporative cooling system is being designed which will provide reliable and cost effective cooling within a close temperature and humidity controlled environment.HIGH PERFORMANCE COOLING AT HALF THE COST, CLEAN AIR SHOW THE WAY AT CHESAPEAKE
Chesapeake is an international supplier of innovative cartons and plastic packaging, labels and leaflets. The machining area for plastic bottling was becoming uncomfortably heated and Chesapeake wanted an alternative to the solution that had been proposed - a ventilation only system quoted at around £100K. After seeing Clean Air’s website, it’s design engineers were invited to quote on a solution which involved evaporative cooling.
The answer came in the form of seven Cool Breeze QAD230 units to be installed through the centre of the factory that formed individually controlled cooling zones over the operational area. The results are impressive, cool fresh air is continually circulated and polluted heated air expelled. Just one unit can lower the internal temperature of 360m2 by up to 16 degrees C, and so it came as no surprise that Chesapeake report that the reach of the cooling has surpassed expectations. Furthermore, despite a challenging installation where the landlord would not allow penetration of the recently reclad roof, the complete solution has been delivered at around half the cost of an alternative ‘ventilation only’ quote from the competition. Chesapeake have now asked Clean Air to look at their office cooling.
TUNSTALL ARE A SHOWCASE FOR THE BEST IN HEATING AND COOLING TECHNOLOGIES
After a visit to the website, Tunstall invited Clean Air to design and quote for a new system to replace their seven aged Hamworthy LPG boilers which provided heating to offices and a part of the production area.
The solution comprised four of the latest energy efficient Hamworthy fully modulating condensing pre-mix boilers, stacked in pairs to save space. Featuring low water content, rapid response, and ultra low standing losses, the units delivered European Class 5 performance for NOx emissions. A new ‘low loss’ flue header system specifically optimised for condensing and high efficiency boiler applications was matched to the boiler modules. To complete the install a new shunt pump and system integrated control panel were fitted. The result is an easily controlled heating system with outstanding performance efficiency.
Pleased with the work Clean Air had done, Tunstall asked for a quote to replace the packaged air-handling units on the rooftop that provided cooling and heating to some of the production area. Also to rationalise the design to include additional cooling to the remaining production areas which had nothing installed. The recommendation to fit ten Mitsubishi twin split air conditioning systems proved a great success. The system uses inverter technology to match output to the exact requirement of the premises. By preventing over-heating or over-cooling, the units save energy leading to a great reduction in running costs.
Clean Air was then asked to design a heating and cooling system for additional offices being refurbished. The solution this time was a Mitsubishi Electric City Multi Heat Recovery VRF system, comprising numerous indoor fan coils connected to high efficiency outdoor condensing units. The solution offered a simple, efficient and flexible answer to the need to change between heating and cooling in order to maintain a constant and comfortable working environment.
Finally Clean Air was asked to turn their hand to Tunstall's canteen, a very large space that reached extreme temperatures in the summer. High power cooling was a necessity but another priority was for fresh air. The solution comprised two Cool Breeze QAD230 evaporative cooling units complete with ducting and grilles strategically placed to deliver cooling exactly as required. Cool filtered fresh air is drawn through the canteen constantly replacing stale heated air which is expelled through roof vents. The result is a comfortable place to eat or work however hot the sun is shining.
The Tunstall projects provided opportunity to showcase the very best in design for many heating and cooling technologies. Effective and efficient, the solutions have proved a tremendous success. Completed over three months, the Clean Air engineers became trusted partners to the Tunstall team.
HIGH EFFICIENCY BOILERS AND HEAT RECOVERY UNITS PROVE A SUCCESS FOR SAILSTORE
Clean Air was commissioned by Sailstore to install a low-pressure hot water system into three new NHS buildings. The right solution was found in four Vaillant Ecotec high efficiency system boilers installed with low loss headers connected to a variety of standard and low surface temperature radiators. The condensing boilers use a heat exchanger to pre-heat the water from the flue gasses and so are highly energy efficient. The system is capable of delivering high volumes of hot water to multiple outlets with an annual seasonal efficiency exceeding 90%.
In addition Mitsubishi Lossnay Heat Recovery ventilation units were fitted to provide fresh air ventilation to the office areas. The units reduce energy consumption by extracting stale air and then warm or cool incoming fresh air by using recovered heating or cooling energy. In addition to reducing energy costs the Lossnay system can save up to 30% on initial capital costs for cooling and heating plant.
The systems have proved a great success, and will provide robust and economical heating and ventilation for years to come.
LOW COST COOLING AND FRESH AIR, CLEAN AIR HAS THE ANSWER FOR SCANTECH
Prompted by a visit to Clean Air’s website, Scantech knew that the time had come to replace their inefficient office air conditioning system with a more cost effective solution. They needed powerful but low cost cooling as well as a continual flow of fresh filtered air.
The perfect answer, evaporative cooling, was at the fingertips of Clean Air’s design engineers but first it was necessary to overcome the significant installation challenge presented by small ceiling voids. The solution, involving numerous smaller branch ducts terminating with grilles, is now able to serve cool fresh air unobtrusively to several offices from just one Cool Breeze QAD230 unit. Scantech’s existing air conditioning system has been removed and Scantech are delighted by the results - improved air quality, a great working environment and incredible energy savings.
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.
The evaporative cooling system can be controlled at the touch of a button and features an Industrial Wall Control (IWC) which allows identification of any faulty cooler in a group which together with the cooler electronic module provides comprehensive fault diagnostics enabling quick repairs.
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."
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Commercial Boilers, Heat Recovery and Ventilation? Tunstall are a showcase for the best in heating and cooling technologies
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