Manufacturing environments present unique climate control challenges that extend far beyond the comfort-focused approach used in commercial settings. At BREDAN Mechanical Systems, our industrial HVAC expertise allows us to develop solutions that optimize both process requirements and worker productivity through carefully engineered climate control systems.
The Complex Climate Demands of Manufacturing Facilities
Manufacturing facilities face distinctive HVAC challenges not encountered in other building types:
Process-Specific Requirements: Many manufacturing processes require precise temperature and humidity conditions to ensure product quality. Variations outside tight parameters can lead to defects, waste, and production delays.
Heat-Generating Equipment: Industrial machinery often produces substantial heat, creating localized hot spots that can affect nearby processes and worker comfort.
Large, Open Spaces: Manufacturing floors typically feature high ceilings and expansive open areas that defeat conventional comfort-cooling approaches.
Indoor Air Quality Concerns: Process emissions, particulates, and other contaminants must be effectively controlled through specialized ventilation strategies.
Varying Occupancy Patterns: Different areas within manufacturing facilities experience dramatically different occupancy densities and activity levels, requiring zone-specific approaches.
24/7 Operations: Many manufacturing processes run continuously, eliminating opportunities for system downtime and demanding exceptional reliability.
Engineered Solutions for Temperature-Sensitive Processes
Manufacturing processes often require more precise environmental control than human comfort alone would dictate. Our approach to temperature-sensitive manufacturing includes:
Microzone Climate Control: Targeted cooling or heating for specific process areas rather than treating entire spaces uniformly.
Specialized Dehumidification: Advanced moisture control systems for processes affected by humidity variations.
Computational Fluid Dynamics Modeling: Data-driven airflow design that predicts and optimizes air movement patterns around sensitive equipment.
Precise Temperature Stratification Management: Strategic approaches to managing the natural temperature layering that occurs in high-bay manufacturing spaces.
Environmental Monitoring Systems: Continuous monitoring with alerts when conditions approach process-critical thresholds.
Harnessing Heat Recovery in Industrial Settings
Manufacturing facilities often simultaneously need cooling in process areas while requiring heating in office or warehouse spaces. This creates unique opportunities for energy recovery:
Process Heat Reclamation: Capturing waste heat from manufacturing equipment to provide space heating or preheat makeup air.
Compressor Heat Recovery: Utilizing heat from air compressors and chillers to support facility heating needs.
Energy Recovery Ventilation: Transferring energy between exhaust and supply air streams to reduce heating and cooling loads.
Hot Gas Reheat: Using rejected heat from refrigeration systems to provide dehumidification without overcooling spaces.
These strategies can reduce energy consumption by 30-50% compared to conventional approaches, delivering substantial operational cost savings.
Success Through Better Climate Control: Wisconsin Precision Manufacturing
A recent project for a Wisconsin precision manufacturing facility demonstrates the impact of specialized climate solutions. The facility struggled with product quality issues during the summer months due to humidity fluctuations affecting their machining processes.
Our team implemented a comprehensive solution featuring:
- Dedicated process area climate control with ±1°F temperature tolerance
- Advanced desiccant dehumidification maintaining a constant 40% relative humidity
- Heat recovery systems capturing process heat for office areas
- Stratification fans to eliminate temperature variations within the workspace
The results were transformative:
- 73% reduction in humidity-related quality defects
- 18% increase in overall production throughput
- 12% decrease in overall energy consumption despite tighter climate control
- Improved worker satisfaction and reduced heat-related productivity losses
Comprehensive Industrial Climate Solutions
BREDAN Mechanical Systems brings specialized expertise in industrial climate control that addresses both the technical demands of manufacturing processes and the comfort needs of the workforce. Our engineering team understands the complex interplay between production requirements, building physics, and human factors that define successful manufacturing climate control.
Request an industrial facility assessment today by contacting BREDAN Mechanical Systems at 262-521-9919 or emailing info@bredanmech.com. Our engineering team will evaluate your specific process requirements, identify opportunities for improvement, and develop custom climate solutions that enhance both production quality and worker productivity.