Case Study Air Mixing reaches record lengths at Freemans

Almost four kilometres of Air Mixing the innovative air induction system from Reznor Uk has been installed for Freemans mail order distribution centre at Peterborough making not only the largest UK application of the system to date, but also the most versatile. All systems were designed and installed by County Plumbing and Heating of Rushden Northamptonshire 01933 413055. Air Mixing’s coverage of four separate warehouse and office locations within the facility has addressed the heating and ventilation requirements specific to each area with results described as ‘brilliant’ by Freemans Premise’s Manager Mike Sulsh.Importantly it has also dramatically reduced energy consumption and improved worker comfort, all at ultra low noise levels. Air Mixing comprises of lightweight fibreglass reinforced plastic ducting which is perforated along its length. Air introduced by unit heaters or air handling units ,flows out of the computer calculated perforations at high speed to produce an immediate mix with the room air but without side effects typical of conventional air distribution systems such as turbulence or preferential air currents. The ducting comes in a choice of more than a dozen colours which for Freemans meant that each location could be individually colour coded. The Air Mixing installation in Freeman’s bulk carton store ( blue duct ) carton pick area ( yellow ) and new packing facility ( cyclamen ) replace’s an ad hoc collection of floor standing oil heaters and a series of electric convectors in the three administrative office’s. The energy saving has been most spectacular in the 18000 m/2 bulk carton store where consumption has been reduced from 13 million to 3 million BTU’s. Draught’s which persisted despite the old system’s high energy input has now been eradicated The bulk carton store consists of high level racking nine metres high which holds stock items from the Freemans catalogue. With worker activity concentrated in the aisles, heat needed to be directed specifically to these areas rather than blown wastefully across the floor space as a whole. Nine main Air Mixing ducts were installed above the racking each fed by a Reznor oil fired heater installed at either end. Ducted legs run from the main duct and are perforated where they pass over the aisles to release air into these spaces only Lower Ceiling For the carton pick area Air Mixing accommodates a much lower ceiling height. Perforated ducts run along the aisles between the low level racking and are supplied by a total of 18 Reznor air handling units. These units are made up of both oil fired heaters and have fresh air and return air ventilation dampers fitted to them. The units are positioned alternately around the perimeter walls and enable the optimum mix of warm and cool air to be maintained for those working in the pick areas. The new packing room contains no racking and is a more typical Air Mixing application. One large duct spans each of the 20 metre wide bays and is perforated with three different hole patterns to cover the 10 metre throw to either side, large holes project air the furthest and the smaller holes direct it progressively closer. Eleven Reznor air handling units with integral mix box supply the necessary input Freemans Mike Sulsh pays tribute to Air Mixing’s flexibility in adapting to the different physical criteria set by each sector of the Peterborough facility Electrical conduits, sprinkler systems and product conveyor systems were already installed so whatever system we selected had to fit around these. County Plumbing and Heating also had to install the system throughout while normal warehouse operations continued with no interruptions of the daily work load. A requirement that involved working nine metres up in the bulk carton store above fork truck operations below. Offices too While Air Mixing is typically applied to large areas such as warehouses, retail sheds or leisure facilities the economy and efficiency benefits enjoyed by Freemans within the distribution centre prompted a look at extending the system to the office area as well Three administrative offices previously heated by hot water convectors are now served by Air Mixing. For aesthetic purposes and to allow for a much lower ceiling height the colour matched white is fitted within the ceiling panels rather than suspended below. The duct connected to the Reznor air handling units are mounted in the plant room area above the office ceilings and is also perforated with smaller holes than usual to provide uniform coverage to the desk workers below The variations in the Freemans application amply confirm the adaptability of the Air Mixing system which also boast simplicity of installation quite operation and easy maintenance (The duct may be easily cleaned when deflated and not in use) As a result other areas of the Peterborough facility are schedule for Air Mixing treatment which will effectively set new installation records for Reznor UK’s air induction system When the project was finished County Plumbing and Heating had installed and commissioned nine kilometres nine kilometres of Air Mixing duct at the Freemans site in Peterborough