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Improving Working Conditions with a Ventilation Upgrade at Greencore Selby
We recently completed a comprehensive industrial ventilation upgrade within the Beetroot Intake area at Greencore’s Selby site in North Yorkshire, delivering significant improvements in environmental control, operator comfort and building protection.
The project was initiated to address persistent issues with excessive humidity, condensation and localised fogging during beetroot processing operations. Relative humidity levels within the space were recorded as high as 95 per cent, with absolute moisture levels considerably higher than external conditions. The combination of steam from cooking processes and uncontrolled airflow had led to poor visibility, uncomfortable working conditions and increasing corrosion risk to the building fabric.
Our brief was to design and install a robust, hygienic and maintainable ventilation system capable of reducing moisture levels while maintaining compliance with BRC food safety standards. Following several design revisions and detailed site discussions, we developed a bespoke solution that significantly enhanced air movement and extraction performance within the area.
The final installation was centred around a new air handling unit delivering 14.0 m³/s of filtered and tempered supply air. To balance the airflow, three new roof-mounted extract fans were installed, providing a combined extract rate of 12.9 m³/s. In addition, five dedicated canopy extract systems were positioned above critical process points, including the storeveyor and both 1-tonne and 5-tonne cooker infeed and exit locations. These canopies were designed to capture steam and moisture at the source, preventing accumulation within the wider space.
To ensure even air distribution, we specified a textile duct system rather than conventional rigid ductwork. The fabric sock solution provides a lightweight, hygienic and easily maintainable method of delivering low-velocity air evenly throughout the area. It can be removed and laundered as required, and we provided the option of a spare sock to allow uninterrupted operation during cleaning cycles. The textile duct was manufactured from food-grade, flame-retardant and bacteria-resistant polyester, mounted on stainless steel rails approximately three metres above floor level.
To prevent winter fogging and maintain stable internal conditions, the supply air system incorporates a low-pressure hot water heating coil. This coil is served from a nearby condensate tank, delivering up to 260 kW of heating capacity. With a design assumption of a 75°C hot water supply, the system is capable of raising incoming air temperature by up to 15°C, ensuring stable operation even in colder ambient conditions. All supply air is filtered to ePM10 60 per cent in accordance with ISO 16890, fully compliant with BRC requirements.
Durability and hygiene were key design drivers. All exposed metalwork, including canopies, extract fans and internal ductwork, was manufactured from 316-grade stainless steel to resist corrosion and meet food production standards. External ductwork was constructed from 304-grade stainless steel for weather resistance. Each canopy incorporates an internal condensate drainage arrangement to prevent dripping, with stainless steel drain lines routed to suitable discharge points.
Control and automation were integrated through a stainless steel control panel installed within the beetroot intake area. The panel features an angled top surface and provides full operational control of the supply and extract systems. Wiring was installed within stainless steel basket containment, with SWA mains cabling and CY control cabling to ensure durability within the processing environment. Automated fan control, temperature regulation and safety interlocks maintain consistent environmental conditions throughout operation.
Installation was carefully phased to minimise disruption to production. The roof-mounted plant was installed during a weekend crane lift to avoid unnecessary downtime. Internal works were completed over a structured programme, including removal of redundant canopies and sealing of disused ductwork. Following installation, full commissioning was carried out to verify airflow rates, heating performance and filtration compliance.
The results have delivered measurable improvements. Humidity levels have been reduced, fogging has been minimised and overall air quality within the beetroot intake area has improved significantly. Operators now benefit from more stable and comfortable working conditions, while the reduced moisture content lowers the risk of long-term corrosion to the building structure.
This project demonstrates our expertise in designing ventilation and air quality solutions for demanding food manufacturing environments. By combining engineering precision with hygiene-conscious material selection and energy-aware heating integration, we delivered a system that enhances both operational performance and long-term reliability.
If your facility is experiencing humidity, condensation or ventilation challenges, our engineering team is ready to support your next project.