Case Study
Ventilation Upgrade – Beetroot Intake Area, Greencore Selby
Overview
Client: Greencore (UK)
Industry: Food Manufacturing
Presence: Design, supply, installation, and commissioning of a new ventilation and extraction system
Project Overview: Penmann Climatic Systems Ltd was appointed by Greencore to upgrade the ventilation system in the Beetroot Intake area at its Selby site, aiming to improve working conditions and address high humidity levels that were causing corrosion. The completed solution improved air quality, reduced fogging and ensured continued compliance with BRC food industry standards.
Project Value Range: £ – Confidential
Penmann Climatic Systems Ltd was appointed by Greencore to upgrade the ventilation system serving the Beetroot Intake area at the company’s Selby site. The project was driven by the need to improve working conditions for site operators and reduce high humidity levels that were contributing to corrosion within the building fabric.
Following several revisions to the design and scope, Penmann delivered a solution that significantly improved air quality, reduced fogging, and maintained compliance with BRC food industry standards.
Project Objectives
The existing Beetroot Intake area was experiencing excessive heat and humidity, particularly during processing operations. Relative humidity levels reached up to 95%, while localised condensation created fogging and poor visibility.
Greencore’s objectives were to:
- Improve operator comfort and working conditions.
- Reduce condensation and humidity-related corrosion.
- Provide effective extraction at key cooking and transfer points.
- Deliver an efficient, maintainable system that meets food hygiene standards.
Penmann designed a bespoke ventilation system capable of providing 8 air changes per hour, ensuring consistent airflow and effective moisture control.
Engineering Solution
The new design comprised a combination of supply and extract systems, including:
- One new air handling unit (AHU) delivering 14.0 m³/s of filtered and heated supply air.
- Three roof-mounted extraction fans providing a combined exhaust rate of 12.9 m³/s.
- Five canopy extract systems installed above key process areas, including the Storeveyor, 1-tonne and 5-tonne cooker infeed and exit points.
The supply air system used a fabric duct (textile sock) for even air distribution throughout the space. This approach provided a lightweight, hygienic alternative to metal ductwork and could be easily removed for cleaning. A spare sock option was offered, enabling continuous operation during laundering cycles.
Heating and Air Quality Control
To prevent fogging during winter operation, the supply system incorporated low-pressure hot water heating. The heating coil was served by a circuit connected to a nearby condensate tank, providing up to 260 kW of heat to raise incoming air temperatures by up to 15°C. The system design assumed a hot water supply temperature of 75°C, ensuring stable operation even during peak ambient conditions.
All air supplied to the space was filtered to ePM10 60% (ISO 16890), fully compliant with BRC food safety requirements.
Materials and Construction
Durability and hygiene were central to the system design. All exposed metalwork, including canopies, fans, and internal ductwork, was manufactured from 316-grade stainless steel. External ductwork was constructed in 304-grade stainless steel to resist corrosion from weather exposure. Each canopy included an internal condensate drain system to capture moisture and prevent dripping. Drain lines were routed in stainless steel to nearby drainage points.
The fabric air socks were produced from food-grade, flame-retardant, and bacteria-resistant polyester, mounted on stainless steel support rails positioned approximately three metres above floor level.
Controls and Electrical Installation
A 304-grade stainless steel control panel with an angled top surface was installed within the Beetroot Intake area, providing full control of the supply and extract systems. All wiring between the panel and system components was enclosed in stainless steel basket containment, with mains cabling using SWA and control cabling using CY specification.
The control system incorporated automated fan control, safety interlocks, and temperature regulation to maintain consistent environmental conditions.
Installation and Commissioning
Penmann supplied, installed, and commissioned the system with minimal disruption to production. All roof-mounted equipment was installed using a weekend crane lift to avoid downtime. Internal installation and testing were completed over a 40-day programme, ensuring the upgraded ventilation was fully operational and validated before handover.
The installation included the removal of existing redundant canopies and sealing of disused ductwork. Final commissioning and testing confirmed airflow rates, heating performance, and compliance with the required filtration standards.
Results and Benefits
The completed system provided Greencore with a significant improvement in air quality and environmental control within the Beetroot Intake area. Operator comfort increased due to reduced humidity and stable temperature control, while the risk of condensation and fogging was greatly reduced.
The use of stainless steel and fabric ducting materials ensured compliance with food hygiene regulations and reduced long-term maintenance requirements. The integration of the condensate heat recovery circuit provided a sustainable and energy-efficient source of heating.
This project demonstrates Penmann’s expertise in designing and delivering ventilation and air quality solutions for the food manufacturing sector—combining engineering accuracy, hygiene-conscious design, and operational efficiency.