Case Study
HVAC Installation for Global UK Snacks Manufacturer
Overview
Client: UK Snacks Manufacturer in Teeside
Industry: Food Manufacturing
Project Overview: Penmann designed, supplied, installed and commissioned a complete HVAC solution for a major UK snacks manufacturing facility, delivering efficient heating, cooling and ventilation across multiple production areas while working within strict electrical power constraints. The project highlights Penmann's expertise in developing energy efficient HVAC systems for complex food manufacturing environments, supported by long term maintenance and technical support.
Project Value Range: £750,000 - £1,000,000
Penmann was appointed to design, supply, install and commission a new HVAC system as part of a major project at this UK Snacks manufacturing facility in Teesside. The project required a complete HVAC solution serving three distinct areas of the facility: the Ingredients Handling Area, Manufacturing Area and New Pellet Warehouse. Each area presented different cooling, heating, industrial ventilation and air distribution requirements.
One of the main engineering challenges was the limited electrical power available for the complete HVAC installation. With less than 300kVA available, Penmann needed to design a system capable of meeting a total cooling requirement of 389kW while keeping the electrical demand within the site limit.
Working closely with the client, project team and equipment manufacturers, Penmann developed a solution that achieved the required environmental conditions with a calculated total plant power consumption of 272.4kVA.
Understanding the Project Requirements
The HVAC design was developed using the Phase 1 HVAC calculations provided for the project. The Ingredients Handling Area required a supply and extract air volume of 10,700m³/h and approximately 50.3kW of cooling. The Manufacturing Area presented the largest demand, requiring 51,100m³/h of supply air and 249kW of cooling. The New Pellet Warehouse required 18,800m³/h of supply air and approximately 89.7kW of cooling.
Together, these areas created a total cooling requirement of 389kW.
The project also required the HVAC system to operate across seasonal conditions, based on a maximum summer design temperature of 23.1°C dry bulb and a minimum winter temperature of minus 2.2°C. While meeting these performance requirements was essential, the restricted electrical supply meant that equipment selection and overall system design needed careful consideration.
Designing Around the Available Electrical Capacity
The electrical power limitation was one of the most important factors influencing the project. As the chiller represented the largest single electrical load, Penmann assessed several ways to reduce its power demand without compromising the required cooling capacity.
The system was designed around a relatively high glycol temperature because chiller efficiency improves as the operating fluid temperature increases. The chiller selection was also based on the specified maximum summer ambient temperature of 23.1°C, allowing the equipment to be selected more accurately around the actual design conditions. Rather than selecting an oversized chiller with substantial unused capacity, Penmann specified equipment closely matched to the calculated cooling load.
Our engineers worked with three different manufacturers during the selection process to identify the most suitable solution for the application. This detailed assessment resulted in the selection of an air-cooled heat pump solution capable of providing the required cooling and heating performance while maintaining the overall HVAC electrical demand below the available 300kVA limit.
The completed design achieved a calculated total power consumption of 272.4kVA.
A 407.6kW Heat Pump Solution
At the centre of the system is an air-cooled heat pump with an integral glycol pump. The chiller provides 407.6kW of cooling capacity based on a 30% propylene glycol and 70% water solution operating at 6°C flow and 12°C return in the specified summer ambient conditions. During colder periods, the same system can provide up to 300.5kW of heating capacity.
Selecting a heat pump solution provided an efficient means of delivering heating without requiring separate heating plant or additional distribution pipework. The solution therefore reduced installation requirements while making effective use of the available electrical capacity. The chiller uses R454B refrigerant and incorporates two hermetic scroll compressors, eight EC condenser fans and electronic expansion valves to support efficient operation.
HVAC for the Ingredients Handling Area
The Ingredients Handling Area is served by a dedicated supply and extract air handling unit capable of delivering 10,700m³/h.
To reduce chiller operation and associated energy consumption, Penmann specified an AHU with an economiser arrangement. The system can switch between recirculation and full fresh air operation according to environmental conditions. When outdoor temperatures allow, the AHU uses fresh air cooling to reduce demand on the mechanical cooling system. The unit incorporates initial and final filtration, a glycol cooling and heating coil and high-efficiency EC fan motors. This approach provides the required environmental control while helping to reduce unnecessary chiller operation and long-term energy consumption.
High Volume Ventilation for the Manufacturing Area
The Manufacturing Area required significantly greater airflow and cooling capacity than the other areas included within Phase 1. Penmann specified two full fresh air handling units, each capable of supplying 25,550m³/h. Using two AHUs rather than a single larger unit provided a more suitable solution for the available plant platform and simplified the physical arrangement of the equipment. Because the extract air volume from the Manufacturing Area was relatively low, an economiser system was not considered appropriate for this part of the installation. Each AHU incorporates high-efficiency filtration, cooling and heating coils and EC fan motors. The two units provide a combined cooling capacity of approximately 249kW.
A separate extract fan was also included within the Manufacturing Area ventilation system.
Environmental Control for the New Pellet Warehouse
The New Pellet Warehouse is served by a further supply and extract AHU delivering approximately 18,800m³/h of supply air. As with the Ingredients Handling Area, the system incorporates an economiser arrangement that allows the AHU to switch between recirculation and full fresh air modes. This allows the system to use free cooling whenever outdoor conditions are suitable, reducing mechanical cooling demand and chiller running hours. The AHU provides approximately 90kW of cooling and incorporates high-efficiency EC fans, two-stage filtration and a glycol cooling and heating coil.
Following changes to the proposed plant layout, Penmann adapted the design to locate the equipment on a single plant platform at the corner of the building. This required an extended internal ductwork system to connect the AHU with the New Pellet Warehouse.
The air distribution arrangement was also revised to accommodate the updated plant location.
Hygienic Textile Air Distribution
Internal air distribution throughout the three areas is provided using textile ducting.
Textile air socks provide several advantages within food manufacturing facilities. They are considerably lighter than traditional metal ductwork, quicker to install and can provide consistent air distribution across large production and storage areas. The textile ducts specified for the project are manufactured from food-quality, fire-retardant polyester material that is resistant to bacteria and mould. The socks can also be removed for cleaning, providing a practical solution for environments where maintaining hygiene standards is a key operational requirement.
Penmann designed the air distribution system around the individual requirements and layout of each area, including revisions required following the relocation of the main plant platform.
Glycol Distribution System
A complete glycol circuit was included to distribute cooling and heating between the heat pump and the four AHUs. The system uses thin-wall stainless steel pipework and includes a pressurisation unit, buffer vessel, isolation valves, strainers, commissioning valves, motorised control valves, vents, drains and test points. The glycol pipework is insulated and finished with aluminium cladding, with removable covers provided for components requiring future service access. The use of 30% propylene glycol provides the necessary protection for the externally located system while supporting the cooling and heating requirements of the installation.
Trend BMS Controls
The project includes a complete Trend BMS control system.
The control panel is positioned centrally on the external plant platform and provides control across the chiller, AHUs and associated HVAC equipment. Effective controls are particularly important for a system of this scale. The ability to manage equipment operation according to actual conditions helps reduce unnecessary energy use while maintaining the required internal environment. The control strategy also supports the economiser operation within the Ingredients Handling Area and New Pellet Warehouse, allowing the systems to take advantage of free cooling whenever conditions permit.
Installation and Commissioning
Penmann was responsible for the complete design, supply, installation and commissioning of the HVAC system. The project scope included the heat pump , four AHUs, Manufacturing Area extract system, glycol circuit, internal and external galvanised ductwork, textile air distribution, electrical installation and Trend BMS controls. Following completion of the installation, the complete system will be tested and commissioned against the project requirements.
Penmann has also included a full day of training during the commissioning period, providing the client’s team with the knowledge required to understand and operate the new system.
Planned Preventative Maintenance
Penmann’s involvement with the project continues beyond installation and commissioning.
A one-year planned preventative maintenance programme has been included, covering the four AHUs and heat pump .
Two scheduled maintenance visits will take place during the first year of operation. The programme includes equipment inspections, operational checks, filter replacement, coil cleaning, glycol testing, electrical checks and detailed assessment of the refrigeration system. The maintenance programme also includes full filter changes according to the specified service schedule. By including maintenance from the outset, Penmann can support the system through its first year of operation and help ensure the equipment continues to perform as designed.
Digital Access to Service Information
The maintenance package includes access to a dedicated customer portal, providing the client with centralised access to service information. The portal provides visibility of service worksheets, planned maintenance bookings, quoted works and emergency breakdown activity. Reports can also be automatically distributed to nominated members of the client’s team. For a large manufacturing facility with multiple HVAC assets, centralised service information provides greater visibility of maintenance activity and equipment history.
Why Penmann Was Selected for this project
The project required far more than the supply of HVAC equipment. The electrical power restriction, different environmental requirements across three areas, large air volumes and changing plant layout demanded detailed engineering input throughout the design process. Penmann has extensive experience delivering temperature and humidity control systems for the food manufacturing sector. This industry knowledge allowed our engineers to understand the operational demands of the facility and develop a solution around the specific requirements of each area.
Our ability to work with multiple equipment manufacturers was also important. By assessing solutions from three manufacturers, Penmann was able to select equipment based on the needs of the project rather than being restricted to a single product range.
The project demonstrates Penmann’s ability to consult, design, specify, supply, install, commission and maintain complete HVAC systems from a single source.
The Outcome
This project represents a significant HVAC installation designed around the specific demands of a major food manufacturing facility. The final design provides 389kW of required cooling across the Ingredients Handling Area, Manufacturing Area and New Pellet Warehouse while maintaining the calculated electrical demand at 272.4kVA, below the 300kVA power limitation.
Through careful chiller selection, the use of heat pump technology, economiser AHUs, EC fan motors and hygienic textile air distribution, Penmann has developed a complete HVAC solution focused on performance, energy consumption and the operational requirements of food production.
From the initial design process through to installation, commissioning, staff training and planned maintenance, this project demonstrates Penmann’s ability to take responsibility for complex food manufacturing HVAC projects throughout their full lifecycle.