Client: Downland Bedding Company, located in the heart of Liverpool city centre.
PHASE 1 :- Main Concerns Our client had recently purchased an unoccupied warehouse next door to the factory, with plans for the new premises to house a large piece of machinery that the company had recently invested in.
Our Director Mark Stephenson attended an onsite visit to meet with the client and 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, capturing the layout of the premises, to enable our system design team to refer to these when deciding on the best possible heating solution for the client.
Photographs show the Anfield Room located in the new warehouse (2100 m3 in size), high uninsulated ceiling at a maximum ceiling height of 10m, and no existing form of heat present. This is the room that our client had identified as the best location for housing the new piece of machinery.
- Provide an industrial heating solution that would provide instant heat to the Anfield Room and minimise the heat lost through the uninsulated roof
- Running costs kept to a minimum
- Project delivery by Mid-December when the new piece of machinery was to be fully operational
OKEL Solution – Industrial Gas Powered Warm Air Heating
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, with sophisticated controls, resulting in more effective heating and lower fuel bills.
Our proposal was to install a combination of Gas Fired Unit Air Heaters provided by our leading manufacturer and the most innovative development on the heating market today. The units are compact and on average 3 times smaller than their predecessors, certain models also benefit from a built-in fan that acts as a destratification fan when the temperature gradient becomes too high at ceiling level. The gradient controls / temperature sensors, identifies the ceiling temperature becoming too hot, forcing the fan to automatically switch on and force 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, we chose to combine the warm air heating system with an additional destratification fan system, responsible for pushing warm air back down to the ground level.
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%.
Commercial PVC strip curtains were fitted as part of the project to prevent heat from escaping via the entrance into the rooms adjacent to the Anfield room.
PHASE 2- After a successful Phase 1 warm air installation, OKEL were approached to deliver Phase 2 in March 2018 as an unused area of the factory was soon to become occupied by machinery and staff as part of the company’s expansion plans.
Dealing with Okel was made easy, Mark was on hand every step of the way, keen to ensure that Okel delivered a solution that fitted our initial brief. The warm air heating system that OKEL installed, enabled us to provide almost instantaneous heat to a large open space within the factory, with a ceiling height in some areas of approx. 10m. After the installation, we had some questions regarding the intelligent thermostatic controls, Okel were quick to provide support, and it was reassuring to know that the personalised customer service continued after the sale.