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Delivering High Care Conditioning and Pressurisation at Howden Joinery, Goole
We are proud to have successfully delivered a high care conditioning and pressurisation system to support the Barberan laminator line at Howden Joinery’s manufacturing facility in Goole, East Yorkshire.
The project required us to design, supply, install and commission a complete environmental control system within an enclosed UPVC-sheeted high care area. The laminating process demanded tightly controlled temperature and humidity conditions, alongside positive pressurisation and high-efficiency filtration to protect product quality and prevent dust or foreign matter ingress.
Working closely with Howden Joinery and the original equipment manufacturer, we developed a system that would maintain stable environmental conditions while aligning with the client’s sustainability objectives. From the outset, the solution needed to deliver process stability, clean air and operational efficiency without reliance on the site’s existing low temperature hot water ring.
Our design centred on a dedicated air handling unit configured with fresh air and return air dampers, allowing a flexible recirculation and ventilation strategy. Two ceiling-mounted extract fans provided controlled air removal, ensuring the high care enclosure remained positively pressurised at all times. Fresh air was drawn through roof-mounted penthouse turrets, tempered and filtered before being introduced into the space via textile air socks. This lightweight distribution system delivered uniform, low-velocity airflow across the laminator area, eliminating hot spots and maintaining consistent conditions.
Heating and cooling were provided by a single reversible air-to-water heat pump chiller, serving as the sole heat source for the system. This approach eliminated the need for a conventional boiler and significantly reduced carbon emissions. Compared with a traditional gas-fired solution, the heat pump system achieved an estimated annual carbon saving of approximately 68 tonnes, directly supporting Howden Joinery’s environmental targets.
The heat pump operated through a mono ethylene glycol circuit, delivering heating and cooling across the full seasonal range while maintaining system efficiency. Internal design conditions were set to ensure a temperature range of 18 to 26 degrees Celsius, with absolute moisture control maintained between 5 and 12 grams per cubic metre. These parameters were critical in preventing dimensional variation within the laminates and ensuring consistent bonding quality.
Air quality formed a major component of the project. The air handling unit incorporated a three-stage filtration system, including HEPA E12 filtration, to meet stringent high care and manufacturing requirements. This level of filtration ensured the controlled environment met OEM expectations and provided confidence in product integrity.
A fully integrated Building Management System control panel was installed within the HVAC plant area, complete with a touchscreen interface for local monitoring. The system was designed to interface seamlessly with the site-wide BMS, enabling remote monitoring, data logging and long-term performance oversight. Control strategies included automatic damper modulation to maintain pressurisation, variable fan speed control to match demand, and multi-point temperature and humidity monitoring. Fault alarms and manual override functions were incorporated to ensure safe and flexible operation.
When the system was not operating at full load, fan speeds were reduced to a controlled minimum to maintain positive pressure, ensuring the high care environment remained protected at all times.
The installation included a Daikin air-to-water heat pump, a 2,500-litre buffer vessel and a glycol pressurisation unit. Stainless steel pipework was installed throughout, incorporating isolation valves and WRAS-approved fittings to ensure reliability and maintainability. Ductwork was fabricated to DW144 standards and internally insulated to enhance thermal performance and streamline installation. Fresh air intake was provided via purpose-built penthouse louvres supported on steel framework.
Delivery and positioning of major plant were completed using a single crane lift, carefully coordinated to minimise disruption to site operations. Internal movement and positioning were managed efficiently, and all electrical connections were installed within galvanised containment systems to ensure long-term durability.
Commissioning and performance validation were completed in July 2022, with the project delivered in line with the agreed programme. The system is now fully operational and supporting stable production conditions within the laminator area.
By combining high-efficiency heat pump technology, advanced filtration and intelligent pressurisation control, we delivered a low-carbon, high-performance solution tailored to a demanding manufacturing process. This project reflects our continued expertise in high care air systems, where environmental precision, process stability and energy performance must work together seamlessly.
If your facility requires high care conditioning, pressurisation control or advanced HVAC integration, our engineering team is ready to support your next project.