Downland Bedding Company

Warm air and Destratification Solutions

Date of Project: Phase 1 November 2016 and Phase 2 March 2018

Client: Downland Bedding Company

Locations: Liverpool

Our client had recently purchased an unoccupied mill next door to the factory and had expansion plans for the new premises to house a large piece of machinery that the company had recently invested in.

OKEL’s Director Mark Stephenson attended an onsite meeting with the client’s Operations Director and Factory Manager to understand their heating requirements; including overall aims of the heating project, temperature requirements for the machinery to operate most effectively, operating hours and number of staff to be based in the neighbouring warehouse.

Whilst on site several photographs and measurements were taken to capture the layout of the premises which would enable our team to design the most effective and efficient heating solution for the client.

The new warehouse (approx. 23,000 sq ft) had an uninsulated roof at a maximum ceiling height of 10m and no existing form of heat present.

The project was to be delivered by Mid-December in enough time for the new machinery to be fully operational.

OKEL Solution

Warm air heating was chosen to heat our client’s premises as its recognised as one of the most cost effective and efficient ways of heating large industrial space. The characteristics of the units contributes to very low energy consumption and high energy savings are achieved in comparison to conventional unit air heaters.

Favoured by many of our clients, warm air heating provides rapid and effective warm air circulation in the winter months and cool air in the summer. The new warm air heating systems are now far more efficient than earlier models and sophisticated controls deliver a more effective overall heating solution and help to lower fuel bills.

OKEL’s proposal was to install a combination of wall mounted natural gas fired warm air heaters and are the most innovative development on the heating market today. 

The units are compact and on average 3 times smaller than their predecessors and benefit from integral fans that recognise when the temperature gradient becomes too high at ceiling level.

OKEL Warm Air Heating System

An expertly designed warm air and destratification system can reduce energy consumption by up to

0 %
Warm Air Factory Heating System

 The gradient controls / temperature sensors identify when the ceiling temperature becoming too hot and switches the fan on automatically to forces the warm air back down to the lower level and preventing heat loss

As an additional measure to combat the loss of heat through the uninsulated roof space OKEL chose to introduce heavy duty destratification fans to be evenly positioned at ceiling height to maximise the even spread of warm air.

The Carbon Trust estimates that the use of destratification fans in industrial buildings with high ceilings and operating a warm air heating system can reduce energy consumption by 20%.

In addition to the warm air and destratification system OKEL fitted clear transparent heavy-duty PVC strip curtains to prevent heat from escaping via the entrances into the rooms adjacent to the warehouse.

Installation and hand over

A pre installation engineer site visit took place ahead of the installation to sign off the exact positioning of the heaters and fans to determine the most even spread of heat whilst considering the layout of the factory.

Prior to the installation detailed risk assessments and method statements were forwarded to our client to review along with gas safe and working at height certification for the team of installation engineers working on site. 

On completion of the installation our lead engineer arranged a training / handover session with our client to ensure they were confident on the capabilities of the heaters and able to maximise the efficiencies by effective use of the intelligent thermostatic controls.

To complete the project electronic copies of Gas Safe and NICEIC certification and user guides for the heaters and fans were forwarded to the client to retain on file.

12 Months after the successful installation of Phase 1, OKEL were approached by our client to deliver a Phase 2 project to heat an unused area of the factory that was also to become occupied as part of our client’s latest expansion plans  – Phase 2 works were completed in March 2018.

Warm Air Heating System