HVAC Case Study
NIFCO Automotive Components

Project requirements

Cooling Nifco UK Limited is a manufacturer of plastic components for the automotive sector. These are designed, developed and manufactured for a vast network of Automotive companies. The company, is part of the wider Nifco Group which is headquartered in Tokyo and operates from more than 35 sites worldwide. Staff and employees at Nifco UK Limited were uncomfortable in the high Summer temperatures. For this reason, they quite rightly reported this discomfort. The plant had no cooling solution installed, only an extraction system with no fresh air supply. The designers specified this system for warehouses but not really suitable for injection moulding process.

The Cooling Solution

Part of the ethos of the company is the ‘Nifco Spirit’. This is a combination of values which define the operation of the business and its members. The Nifco Spirit highlights the importance of ensuring the well-being of its employees, in relation to being a successful business. Considering this, Nifco UK Limited sought to rectify the issue of employees’ discomfort by investigating appropriate cooling solutions.

Production management then researched traditional forms of cooling. They therefore initially considered the installation of four mechanical air handling units and heat pumps. However, this system required heavily intrusive ductwork within the roof space and significant floor space.

For this reason the management contacted Ambient HVAC and seriously considered evaporative cooling.
The project posed real challenges as the power supply of the factory was limited and they esteemed power upgrades at a cost of £500k.

Various specialists proposed a number of solutions from standard DX cooling to supply air displacement with energy recovery and chilled water based cooling with free cooling capability. Ambient HVAC analysed the building’s heat load and suggested installation of Breezair TBSI 580 units and extraction fans on the factory roof.

Comparing the air cooling possibilities

The company required a competitive tender process. This way, they reviewed the pros and cons against Ambient evaporate cooling based ventilation design. The following comparisons were made.

Installation

Ambient designed a system to negate the heat load whilst increasing the air quality / volume by up to 7 times. They strategically positioned a number of localised systems to provide maximum effectiveness without impacting on the working areas/production of the plant. They installed 28 Breezair TBSI 580 + 10 extractions fans (to remove heat and stale air); high level, high velocity supply ducts, diffuse fresh cool air to the occupancy level for comfort and air quality. Displacement effect ensures reliable and efficient air management to zone to suite the varying loads within the production areas. Bespoke controls and Inverter drive technology ensure minimising energy input and monitored throughout.

Results

Uncomfortable summer temperatures that could reach 35°C in the factory, turned to a more comfortable 24°C, improving thermal comfort and employees’ well being. A criteria for selection of the Breezair system is that it can be easily added to if required compared with traditional mechanical air handling systems.

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