Case Study
High Risk Area Ventilation – UPB Products Ltd
Overview
Client: UPB Products Ltd
Industry: Manufacturing
Presence: Temporary Ventilation and Pressurisation System
Project Overview: Penmann delivered a temporary ventilation and pressurisation system for a high risk area at UPB Products Ltd, using an external air handling unit to maintain controlled airflow and prevent contamination. The system achieved stable positive pressure, met required filtration standards, and operated reliably with minimal disruption to site operations.
Penmann was appointed to deliver an industrial ventilation solution for a high risk area within UPB Products Ltd’s facility. The objective was to create a controlled environment through positive pressurisation, ensuring that airborne contaminants were prevented from entering the space. The area presented specific operational requirements, including defined internal volume, access points and filtration standards. Maintaining stable pressure and air quality was essential to support safe and compliant operation.
Penmann provided a complete solution, including equipment selection, ductwork installation, commissioning and removal at the end of the hire period.
The Challenge
The high risk area had a volume of approximately 115 m³ and included multiple openings, including four access hatches and a sanitising tunnel. These openings created potential paths for contamination, making consistent pressurisation a key requirement.
The system needed to maintain a positive pressure of approximately 5 Pascals while delivering filtered air to meet F7 filtration standards. In addition, the internal environment was required to operate within a temperature range of 22 to 26°C, although active temperature control was not initially required.
The solution had to be reliable, straightforward to operate and capable of maintaining consistent performance throughout the hire period.
Penmann’s Solution
Penmann supplied and installed an NR-AHU150 external air handling unit, selected for its ability to deliver the required airflow, filtration and pressurisation.
The unit was designed for external installation, allowing it to supply conditioned air into the controlled space without occupying internal production areas. This approach ensured minimal disruption to existing operations while maintaining a clear and effective airflow path.
The system delivered a nominal airflow rate of 15,000 m³/hr, providing sufficient volume to maintain positive pressure within the space while compensating for air loss through hatches and access points.
Air Handling and Filtration
A key requirement of the project was to ensure that all air entering the high risk area was filtered to the required standard. The system incorporated G4 pre-filtration and F7 secondary filtration, removing particulates and maintaining air quality within the space. Filtered air was supplied into the area through a network of ductwork, ensuring even distribution and consistent pressurisation. The design ensured that clean air flowed outward through openings, preventing unfiltered air from entering the space.
This approach created a controlled environment aligned with the operational requirements of the facility.
Ductwork Installation
Penmann designed and installed a spiral galvanised ductwork system to connect the air handling unit to the high risk area. The ductwork was sized and configured to support the required airflow while maintaining efficiency and structural integrity. All ducting was installed to ensure minimal resistance and balanced air distribution, allowing the system to operate effectively without excessive energy demand.
The installation was completed in a structured manner, ensuring that all components were securely fixed and aligned with the building layout.
Control and Operation
The NR-AHU150 unit incorporates inverter-driven EC fans and an advanced control system, allowing airflow to be adjusted to maintain the required pressure within the space. Integrated sensors monitor operating conditions, ensuring that the system responds to changes in demand and maintains consistent performance. The system operates automatically, requiring minimal intervention from site personnel.
Although the unit is capable of providing both heating and cooling, it was configured for ventilation and pressurisation only, as temperature control was not required for this application. The system retains the flexibility to incorporate temperature control if needed in future.
Installation and Commissioning
Penmann managed the full installation process, including delivery, positioning of the air handling unit and installation of all associated ductwork. Following installation, the system was commissioned to ensure that it achieved the required airflow, filtration and pressure levels. This included testing and balancing to confirm that the high risk area was operating under the correct positive pressure conditions.
Once commissioned, the system was handed over to the client with guidance on operation and performance.
Performance and Results
The ventilation system successfully established and maintained the required pressurisation within the high risk area. Airflow remained consistent, and filtration levels met the specified requirements, ensuring that the environment remained controlled and protected. The system operated reliably throughout the hire period, with minimal intervention required. The external installation of the air handling unit allowed the system to function effectively without impacting internal operations.
By delivering a controlled airflow and maintaining positive pressure, the system supported safe working conditions and helped protect the integrity of the process within the space.
Key Benefits
Effective Pressurisation
The system maintained a stable positive pressure, preventing the ingress of unfiltered air into the high risk area.
High Quality Filtration
G4 and F7 filtration ensured that all supplied air met the required standards for cleanliness.
Reliable Operation
The air handling unit delivered consistent performance throughout the hire period, supporting ongoing operations.
Minimal Disruption
External installation and efficient ductwork design ensured that existing processes were not impacted.
Flexible System Design
The system can be adapted to include temperature control if required, providing future flexibility.
Turnkey Delivery
Penmann managed the full project, from equipment supply and ventilation installation through to commissioning and deinstallation.
This project demonstrates Penmann’s ability to deliver effective ventilation system design and pressurisation solutions for controlled environments. By combining robust equipment with a carefully designed ductwork system, Penmann provided UPB Products Ltd with a reliable and efficient solution tailored to their requirements. The successful delivery of this project highlights the importance of well-designed airflow systems in maintaining controlled environments within manufacturing facilities.
For more information on industrial ventilation, air handling and environmental control solutions, contact Penmann today.