Case Study

Hotel Chocolat, Hadley Park – Air Conditioning for West Wing, Velvetiser and Despatch Areas

Overview

Client: Hotel Chocolat

Industry: Food Manufacturing

Presence: Design, supply, installation and commissioning of a full air conditioning system

Project Overview: Penmann Climatic Systems Ltd designed and installed a full air conditioning and ventilation system for the Hotel Chocolat site at Hadley Park, covering several production zones with specific temperature needs. A revised proposal also introduced an optional steelwork platform above the Despatch area to support the external chiller and air handling plant.

Project Value Range: £600,00 - £800,000 range (plus optional steelwork platform £110,000)

Penmann Climatic Systems Ltd was appointed to design and install a comprehensive commercial air conditioning and ventilation solution for the Hotel Chocolat facility at Hadley Park. The project covered multiple production and processing zones including the West Wing, Velvetiser and Despatch areas, each with distinct temperature requirements to support product quality and staff comfort. Following an initial site visit by Damian and John Kirwin, Penmann developed a revised proposal which incorporated an option for a purpose-built steelwork platform above the Despatch area to house the external chiller and air handling plant.

Project Background

The facility contained two distinct zones: the production area, where process loads generate substantial heat, and the packing area, where stable and comfortable conditions are vital for both product integrity and workforce well-being. Traditional mixing ventilation methods were considered unsuitable due to the high roof volume and heat generation. Instead, Penmann proposed a displacement ventilation approach, building on experience from comparable installations and validated load estimates from existing systems in adjacent bays.

Project Scope

The system was designed to maintain precise temperature control across several production zones:

  • West Wing Ground Floor: 23–25°C
  • West Wing First Floor: 18–20°C
  • Velvetiser Ground Floor: 15–17°C
  • Velvetiser First Floor: 23–25°C
  • Despatch Area: 18–20°C
  • Main Production (beneath new mezzanine): 18–20°C

Ventilation was also provided for the Velvetiser first-floor changing area.

The installation included:

  • 1 No. air-cooled chiller
  • 1 No. chilled glycol circuit
  • 3 No. air handling units (AHUs)
  • 5 No. insulated supply ducts
  • 5 No. insulated return ducts
  • 5 No. textile sock distribution systems
  • 1 No. fan coil unit for the Despatch area

Design and Equipment

A Trane air-cooled chiller using R1234ze refrigerant was selected for its low Global Warming Potential (GWP 7). With a 700 kW cooling capacity, the system delivers propylene glycol at 1°C to each AHU and the Despatch fan coil. Three air handling units were installed, each fitted with G4/F7 filtration, chilled water cooling coils and supply fans. The design incorporated economiser sections to enable free cooling during suitable external conditions, significantly reducing mechanical cooling demand. Controlled via the Building Management System (BMS), the economisers automatically switch between recirculation and full fresh air modes based on temperature conditions.

Air Distribution

Air sock distribution systems were used throughout the West Wing and Velvetiser areas. These textile socks provided hygienic and efficient air delivery, ideal for food manufacturing environments. Compared with conventional metal ductwork, the sock system offered advantages in cost, weight, hygiene, and ease of maintenance, as they can be removed and cleaned periodically. In the Despatch area, a hygienic fan coil unit provided dedicated local air conditioning. The unit was designed with cleanable components, a stainless-steel drain tray, and noise levels limited to 60 dB(A) at 3m.

Steelwork Platform

An optional 21m x 13m galvanised steel plant platform was proposed above the Despatch area roof to accommodate the external chiller and AHUs. Access was provided via an external staircase along the factory’s west elevation. The design included open mesh decking for drainage and safety, with installation scheduled for weekend hours to minimise disruption to production.

Controls and Operation

A Delta BMS system was installed to manage and monitor all equipment, including chiller operation, AHU control, damper positioning, and free-cooling sequences. The BMS featured a graphic HMI touchscreen for ease of use, ABB inverter drives for energy efficiency, and comprehensive temperature and pressure monitoring. The control panels were mounted externally on the new plant platform in weatherproof enclosures, with all wiring contained in galvanised steel basket systems.

Environmental and Efficiency Considerations

The system design took into account both operational efficiency and sustainability:

  • Use of low-GWP refrigerant (R1234ze)
  • Free cooling capability through economiser sections, reducing compressor use
  • High-efficiency EC fans and inverter drives
  • LED lighting and optimised heat load calculations for accurate plant sizing

These measures reduced overall energy consumption while maintaining the tight temperature control required for chocolate production and packaging.

Installation and Commissioning

All plant and ductwork were installed by Penmann’s in-house engineers. Crane lifts were carried out during weekend hours for the positioning of the chiller, AHUs, and steelwork platform. The installation included all associated electrical and control works, condensate drainage, and commissioning. A full day of operator training was provided to Hotel Chocolat’s on-site team to ensure confident system management post-handover.

Outcome

The completed air conditioning system delivered precise and reliable environmental control across all production zones. The integration of energy-efficient components and a responsive BMS ensures consistent performance, reduced operational costs, and compliance with the client’s sustainability objectives.

The project demonstrates Penmann’s ability to deliver complex climatic control solutions within active food manufacturing environments, balancing efficiency, hygiene, and maintainability.