Newsome’s HVAC Solution for a Major UK Chocolate Manufacturer

In chocolate manufacturing maintaining precise temperature control is essential. High ambient temperatures can cause significant challenges, not only affecting the quality of the chocolate but also creating an uncomfortable and potentially unsafe working environment. For Newsome’s client, a leading UK-based chocolate manufacturer, managing temperatures within the main processing hall had become increasingly problematic, particularly during the summer months.

The Challenge: Managing High Temperatures in the Main Processing Hall

The existing industrial ventilation system was outdated and struggled to cope with the high internal heat loads generated by processing equipment and external summer temperatures. This led to indoor conditions that frequently exceeded 28°C, causing operational issues for temperature-sensitive control equipment and reducing productivity. Ensuring a comfortable and stable indoor environment was a top priority, with a target temperature of 25°C, regardless of outside conditions.

Recognising the limitations of their current system, the client turned to Newsome for an engineered solution capable of delivering consistent and efficient cooling. Our objective was to design, supply, and install a turn-key air handling and distribution system that could efficiently regulate indoor temperatures and improve working conditions.

The Objective: Delivering an Effective Cooling Solution

The primary goal of the project was to implement a high-performance HVAC system that could maintain a maximum indoor temperature of 25°C, even when external temperatures exceeded 28°C. This required a solution that was not only powerful but also energy-efficient, ensuring optimal temperature control without escalating operational costs.

Our approach focused on:

• Designing a tailored air handling system to manage high heat loads.
• Ensuring uniform air distribution across the main processing hall to eliminate hotspots.
• Integrating energy-efficient features to reduce operating costs.
• Minimising disruption to ongoing production during installation.
• Ensuring full compliance with health, safety, and environmental regulations.

With these objectives in mind, our engineering team began a comprehensive site assessment, evaluating the existing ventilation system, heat load profiles, and spatial constraints. This enabled us to design a bespoke solution that addressed both the immediate cooling requirements and the long-term efficiency goals of the facility.

The Solution: Installation of the Airfinity AHU & Cooling System

To achieve the desired cooling performance, Newsome installed an Airfinity Air Handling Unit (AHU) IC270, a state-of-the-art air handling solution known for its efficiency and robust performance in industrial environments. The system was selected for its ability to deliver high air volumes, advanced air distribution, and energy-efficient cooling capabilities.

Key Specifications of the AHU IC270:

• Air Volume: 11.66m³/s, providing 4.94 air changes per hour.
• Net Cooling Capacity: 241.08 kW, ensuring sufficient cooling power to offset internal heat gains.
• Energy Efficiency: Utilised free cooling through modulating dampers with enthalpy control, allowing the system to leverage cooler external air whenever possible.
• Advanced Air Distribution: Integrated a FabricAir textile sock system for even air distribution, preventing hotspots and ensuring a uniform temperature across the hall.

Installation Process:

The installation was meticulously planned to minimise downtime and ensure seamless integration with the existing infrastructure. This process included:

• Ground and Radar Surveys: Conducted comprehensive surveys to identify optimal placement for the AHU, ensuring efficient airflow and ease of maintenance.
• Removal of Existing System: Safely decommissioned and removed the outdated ventilation equipment without disrupting production schedules.
• Structural Enhancements: Designed, manufactured, and installed a steel gantry to securely support the new AHU system.
• Insulated Ductwork: Custom-designed and installed rigid insulated ductwork to minimise thermal losses and ensure efficient air delivery from the AHU to the processing hall.
• Commissioning: Conducted extensive testing and fine-tuning of the AHU, ductwork, and air distribution system to ensure optimal performance from day one.

Energy Efficiency and Cost Savings

One of the standout features of the new HVAC system was its energy efficiency. The incorporation of enthalpy-controlled dampers allowed the AHU to utilise cooler outdoor air whenever possible, reducing reliance on active cooling and lowering energy consumption. This free cooling capability is particularly effective during spring and autumn months when external temperatures frequently drop below indoor setpoints.

Additionally, the advanced textile sock air distribution system ensured that cooled air was evenly distributed, eliminating the need for high-output fan systems and further reducing energy usage. This approach not only helped in maintaining consistent temperatures but also contributed to significant operational cost savings.

The high-performance insulation used in the ductwork minimised thermal losses, ensuring that all cooled air reached the processing areas efficiently. Overall, the system was designed to offer a low total cost of ownership by combining high efficiency with reduced maintenance requirements.

The selected Trane packaged unit combines heating, cooling, and fan functionality in a single unit and is ideal for most types of commercial & industrial buildings. The unitary system features integrated controls, engineered to create the best possible comfort environment and offering multiple configurations of heat recovery to ensure the client benefits from the most efficient system, with the lowest operating costs.

The Outcome: Enhanced Temperature Control and Working Conditions

The installation of the Airfinity AHU IC270 was a complete success. Post-installation assessments showed that the system effectively maintained the target indoor temperature of 25°C, even during peak summer conditions when external temperatures exceeded 28°C. This was a significant improvement over the previous system, which frequently struggled to keep temperatures within safe operational limits.

The uniform air distribution achieved through the FabricAir textile sock system improved overall comfort for employees, reducing complaints of heat stress and creating a safer, more productive working environment. Moreover, the energy-efficient design of the AHU and the use of free cooling significantly reduced the facility’s energy consumption, translating to lower operational costs. Compliance with health, safety, and environmental regulations was verified through a comprehensive commissioning process, ensuring that the system met all necessary standards. The client was highly satisfied with the outcome, noting both the improved working conditions and the cost-efficiency of the solution.

Client Testimonial

“Our experience with the Newsome’s projects team has been very positive. Robert’s communication was excellent. He ensured that we were aware of installation progress throughout and that the installers adhered to the site EHS and food safety rules. His organisation and involvement of the local team made it easy to support the installers, to ensure that the project was delivered on time.”

“We have been very pleased with the way the project has been executed and found it very helpful to have an allocated project manager. We felt this made the project run smoothly, since there were so many challenging aspects to the installation and we are extremely happy with the system design and installation and are now excited to have a cooler factory environment for the site team!”

The successful completion of this HVAC project highlights Newsome’s expertise in delivering tailored industrial cooling solutions that balance performance, efficiency, and cost-effectiveness. By combining advanced air handling technologies with energy-efficient design, Newsome were able to transform the climate control capabilities of a leading UK chocolate manufacturer. If your facility is facing challenges with temperature management, dehumidification or ventilation, contact Newsome today to discuss how our bespoke HVAC solutions can optimise your operations and enhance your working environment.

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