Case Study

Air Handling Solution for Pattemores Dairy Ingredients Filling Room

Overview

Client: Pattemores Dairy Ingredients in Crewkerne, Somerset

Industry: Food & Beverage Production – Dairy

Project Overview: Climate-Controlled Filling Room Installation

Pattemores Dairy Ingredients, a specialist in dairy-based food components, required a high-performance air conditioning system for their newly constructed filling room at their Somerset production facility. Maintaining a consistently low temperature within this space was critical to preserving product quality and meeting stringent hygiene and safety standards.

 

Penmann was appointed to deliver a tailored air handling solution capable of maintaining internal temperatures between 10°C and 15°C, with optimal performance nearer the lower threshold. This project reflects Penmann’s ongoing commitment to providing energy-efficient, reliable industrial ventilation and climate control solutions for the UK’s food manufacturing industry.

Project Overview

The system was designed to meet strict climate control parameters while providing long-term durability and hygiene performance. The primary cooling medium for the system was a -1°C glycol solution, supported by a recirculating air handling unit (AHU) positioned externally on an existing plant platform.

Following an initial site survey by Penmann’s engineering team, the system specification was revised to improve installation efficiency and match operational requirements more closely. The external AHU was upgraded to a weatherproof specification, and air ducting lengths were recalculated to account for the new location.

Equipment Supplied and Installed

The final solution included:

  • Externally mounted AHU, complete with chilled water-cooling coil, mixing box, fresh air intake, and internal return air connection.
  • Textile sock air distribution system, ideal for hygienic environments with low velocity airflow, reducing cold draughts and supporting even temperature distribution.
  • Galvanised ductwork, fully insulated and clad for durability and performance.

The air handling unit was designed to deliver 5.0 m³/s of supply air and to re-circulate approximately 4.7 m³/s, with an additional 0.3 m³/s of fresh air introduced to maintain room pressurisation.

 

  • Advanced filtration system, with ePM10 (M5) primary filters and ePM1 (F9) secondary filters meeting ISO16890:2016 standards.
  • Control panel and electrical works, including inverter-driven fan motor and all wiring between system components.
  • Full commissioning of all installed plant.

Sock ducts were specified to distribute air evenly throughout the filling room, providing a highly sanitary and energy-efficient solution commonly used across the food production sector.

Key Technical Highlights

The system delivered by Penmann to Pattemores Dairy Ingredients was designed with precision to meet the strict demands of a controlled filling environment. At the heart of the installation is a chilled water-cooling coil, capable of providing approximately 68kW of cooling. This cooling capacity is matched to the room’s calculated heat gain, ensuring that even in periods of high ambient temperature or during intense production activity, the system can reliably maintain the required internal conditions.

Air movement is achieved through an 11kW centrifugal backward-curved fan motor, carefully selected to ensure robust airflow performance while maintaining energy efficiency. The fan delivers a consistent supply volume of around 5.0 cubic metres per second, providing adequate circulation to meet the cooling demands and air change rate of the filling room. This airflow rate was determined in line with a detailed assessment of internal heat gains, including contributions from machinery, lighting, and personnel, which collectively amounted to a sensible heat load of 35.82kW, with an additional 0.47kW of latent heat identified through infiltration and occupant moisture generation.

  • Cooling Capacity: ~68kW provided via chilled water coil
  • AHU Fan Motor: 11kW centrifugal backward-curved design
  • Filtration: Dual-stage, compliant with modern air quality standards

 

Air quality within the space is protected through a dual-stage filtration system. This includes an ePM10 50% filter (comparable to the previously classified M5) for primary filtration, followed by an ePM1 85% secondary filter, both of which conform to ISO16890:2016 standards. These filters are vital in a food-grade environment, where fine particulate control is essential to avoid contamination. To maintain a cleanroom-like pressure regime, a small but continuous volume of fresh air—approximately 0.3 cubic metres per second—is introduced to the system. Air is distributed via textile sock ducting, fabricated from food-safe, fire-retardant, anti-microbial polyester. These ducts are manufactured in a D-profile to suit the ceiling height and room layout, promoting even airflow with low velocity to avoid draughts or turbulence that could impact filling operations.

 

 

  • System Design Heat Load: 35.82kW sensible and 0.47kW latent
  • Fresh Air Introduction:3m³/s for room pressurisation
  • Sock Ducting: Fire-retardant, anti-microbial polyester textile, D-profile to suit room dimensions

Design Considerations

A number of design challenges were identified and addressed:

Condensation Control: The AHU was built with high-performance insulation to prevent internal condensation. However, the aluminium frame extrusions were recognised as a potential condensation risk under high ambient moisture conditions. This risk was mitigated through system layout and material selection.

Hygienic Airflow: Sock ducts were selected to prevent contamination risks associated with hard ducting and to ensure ease of cleaning. This also allowed for flexible installation in a room with ceiling height constraints.

Heat Gain Assessment: Penmann worked closely with Pattemores team to estimate heat loads from machinery, lighting, infiltration, and occupancy. These estimates informed system sizing and selection of the appropriate cooling medium.

Room Pressurisation: The AHU design accounted for known openings in the room envelope, ensuring positive pressure was maintained to help prevent ingress of airborne contaminants.

Result

Penmann successfully delivered a turnkey solution that provides consistent temperature control, improved air quality, and energy-efficient operation—all vital for a filling environment in a dairy processing facility. The project was completed to the client’s satisfaction and met all hygiene and operational requirements.

The system is now fully operational, offering Pattemores the reliability and performance needed to support their daily operations while meeting industry compliance standards.

Thinking About Your Next Ventilation, Humidity Control or Cooling Project?

Whether you operate in dairy, chilled foods, or wider food and beverage production, Penmann can design, supply, and install bespoke climate control systems that help you stay efficient, compliant, and productive. Contact our team today to discover more.