Case Study

High Care Conditioning and Pressurisation – Howden Joinery, Goole

Overview

Client: Howden Joinery Ltd

Industry: Manufacturing

Presence: Design, supply, installation, and commissioning of high care air conditioning, heating, and pressurisation system.

Project Overview: Penmann Climatic Systems Ltd designed and installed a high care conditioning and pressurisation system for the Barberan laminator line at Howden Joinery’s Goole site. The system provides accurate temperature and humidity control, high efficiency air filtration, and positive pressurisation to maintain stable conditions and protect product quality.

Project Value Range: £300,000-£500,000

Penmann Climatic Systems Ltd was appointed to design and install a new high care conditioning and pressurisation system to support the Barberan laminator line at Howden Joinery’s Goole site.

 

The new system was designed to deliver precise temperature and humidity control within an enclosed UPVC-sheeted high care area, ensuring the laminating process could operate under stable environmental conditions. The system also required high efficiency air filtration and positive pressurisation to prevent dust and foreign matter ingress, protecting product quality throughout the process.

Project Objectives

Working closely with Howden Joinery and the original equipment manufacturer (OEM), Penmann developed a system that:

  • Provides stable temperature and humidity to maintain consistent laminating quality.
  • Ensures positive pressure to prevent external contamination.
  • Incorporates HEPA E12 filtration for clean air delivery.
  • Integrates seamlessly with the site-wide BMS for remote monitoring and control.
  • Uses low-carbon heat pump technology to meet the client’s CO₂ reduction targets.
  • Avoids reliance on the site’s LTHW ring by using an independent heat source.

Design Solution

The system was built around a single air handling unit (AHU) with fresh air and return air (FA/RA) dampers, serving a recirculation/fresh air ventilation system designed for flexibility and efficiency.

Two ceiling-mounted extract fans provided balanced air removal, maintaining the desired positive pressure within the enclosure.

Fresh air was drawn through roof-mounted penthouse turrets, tempered, and filtered before entering the controlled space. Distribution was achieved using lightweight textile air socks, which provided uniform low-velocity airflow across the laminator area. Four 865 mm diameter socks were suspended from an 1800 mm diameter header, ensuring even air movement and temperature balance.

Heating and Cooling

A single reversible air-to-water heat pump chiller was installed to provide both heating and cooling. This served as the sole heat source, eliminating the need for a conventional boiler system and significantly reducing carbon emissions.

Compared to a traditional gas-fired boiler, the heat pump solution achieved an estimated CO₂ saving of approximately 68 tonnes per annum, meeting Howdens’ environmental sustainability objectives.

Heating and cooling were provided via 25% mono ethylene glycol circuits operating at 44°C/55°C (heating) and 6°C/12°C (cooling).

Air Quality and Filtration

To maintain strict environmental control, the air handling unit incorporated a three-stage filtration system:

  • Primary Filtration: Coarse 70% (ISO 16890, formerly G4)
  • Secondary Filtration: ePM1 80% (ISO 16890, formerly F9)
  • Tertiary Filtration: HEPA E12 (EN1822, 99.5% efficiency)

This ensured high care air quality in line with OEM and BRC manufacturing requirements.

The design also provided an absolute moisture control range of 5–12 g/m³, maintaining consistent material performance and preventing dimensional variations in laminates.

System Performance

Internal Design Conditions:

Temperature: 18–26°C

Moisture: 5–12 g/m³

External Design Conditions:

Summer: 25.4°C db / 18.3°C wb

Winter: -5°C db / -5°C wb

Total Air Volumes:

Supply Air Volume: 6.5 – 14.5 m³/s

Process Extract: 4.5 m³/s

Pressurisation Air Volume: 2 m³/s

Exhaust Volume: 8 m³/s

The system was designed with flexibility to accommodate fluctuations in external temperature while maintaining stable internal conditions without rapid temperature swings.

Controls and Integration

A digital Building Management System (BMS) control panel was installed within the HVAC plant area, complete with a colour touchscreen HMI to allow on-site monitoring and control. The system was fully compatible with Howden’s existing site-wide BMS, enabling remote access and data logging for ongoing performance management. The control strategy included automatic modulation of the fresh air dampers to maintain pressurisation, along with fan speed adjustment based on air volume demand. Temperature and humidity were monitored at multiple points within the system to ensure accurate environmental control. Fault alarms were incorporated for the supply and extract fans, the heat pump, and the glycol pressurisation unit, all of which could be viewed through the HMI interface. The panel also provided manual override capability for both damper positioning and valve operation. When the system was inactive, fan speeds were automatically reduced to a low, controlled level to maintain the required pressurisation, ensuring the high care area remained protected at all times.

Installation and Commissioning

The installation included a Daikin air-to-water heat pump, a 2,500-litre buffer vessel, and a glycol pressurisation unit. All pipework was manufactured from stainless steel and installed with isolation valves and WRAS-approved fittings to ensure reliability and ease of maintenance. Ductwork was fabricated in galvanised steel to DW144 standards, featuring 9 mm internal Armaflex insulation to improve efficiency and simplify installation. Two penthouse louvres, each measuring 1,200 mm by 1,200 mm by 1,500 mm, were installed for fresh air intake, supported by a purpose-built steel frame.

Equipment delivery and positioning were managed using a single crane lift, while internal movement was handled on wheeled dollies to minimise disruption. Electrical connections between the control panel and all system components were installed using galvanised steel basket containment for durability and organisation. Commissioning and performance testing were completed in July 2022, following a start date in week 21, achieving practical completion by the end of June 2022 as programmed.

Project Outcome

The system successfully achieved all design objectives, providing Howden Joinery with a high care conditioning solution that ensures precise control over air quality, temperature, and humidity.

Through the use of heat pump technology, Penmann delivered a low-carbon, energy-efficient installation that supports Howden’s sustainability goals while maintaining stringent manufacturing quality standards.

This project further demonstrates Penmann’s expertise in designing and delivering complex high care air systems that integrate environmental performance, process stability, and long-term operational efficiency.