Case Study

KP Snacks displacement air conditioning

Overview

Client: KP Snacks

Industry: Food

Project Overview: Multiple benefits for leading snacks business following upgrade to displacement system

Outcomes

  • The conversion is estimated to reduce electricity costs by more than £115,000 per annum alone
  • Service and maintenance costs have also been significantly reduced, as there is no requirement to remove and launder socks
  • Filter life has been extended and the refrigeration plant is only required to operate for 30% of the year
  • Staff also benefit from the improved working environment. This project had a payback time of just two and a half years

Challenges

KP Foods had an existing plant serving two packing halls with an area in excess of 13500m2 and a cooling load greater than 1MW.

The existing system, which utilised air sock distribution, was unable to meet cooling requirements and also proved difficult to maintain.

Solutions

We redesigned the system to operate as a displacement system. The air handling plants were reduced by 50%, with any retained units being refurbished.

The sock air distribution system was replaced with floor-mounted displacement terminals. Some terminals were mounted above production equipment due to floor space restrictions.

The refrigeration was replaced with a new plant approximately one-third the size of the original.

The new system only requires a supply air temperature of 17°C to 26°C in the occupied space, enabling the use of free cooling for most of the year. It also has the added benefit of minimising the amount of recirculated room air.

Conclusion

In conclusion, the displacement air conditioning upgrade for KP Snacks has reduced electricity costs by over £115,000 annually and cut service and maintenance costs. The system now operates efficiently, with the refrigeration plant running only 30% of the year, extending filter life and improving the working environment. The redesign included reducing air handling plants by 50%, replacing sock air distribution with floor-mounted displacement terminals, and utilising free cooling for most of the year. These improvements led to a payback time of just two and a half years.