HVAC Case Study
Huhtamaki

The industrial plant

Huhtamaki group (worldwide packaging company) has three operating facilities in the United Arab Emirates. One facility is located in Ras Al Khaimah and two in Jebel Ali Free Zone. Two facilities are into flexible packaging business and the third one manufactures printing cylinders. The three industrial plants employ above 550 people and occupy 48 500 square meters in total.

The air conditioning system

The main aim for the first project (in the Jebel Ali plant), was to reduce the power consumption of the Air Handling Units with DX type condensing units. The fresh air requirement for the AHUs is very high due to the treatment process implemented in the plant, (including Chromic acid).

Moreover, UAE temperatures in the summertime can overcome 50°C. This results in extremely high power consumption for the Air Handling Unit to cool the air.
Huhtamaki-UAE approached Climagulf, official distributor of Seeley International products in the UAE, to try and solve the problem. They suggested four Climate Wizard Indirect Evaporative Air Coolers (model CW-H15) directly coupled to four ofthe Air Handling Units for their Outside Air component. To evaluate the performance, data loggers were installed to track:

• ambient air temperature,
• temperature of the air supplied by one of the Air Handling Units,
• room temperature inside the industrial plant (operator level).

Water re-use

Huhtamaki-UAE Management was concerned about Climate Wizard water consumption.

“When Climagulf approached us with Indirect Evaporative Cooling solution, we were concerned that the machines would have consumed too much water, which can be a real issue in UAE. In fact, AHU produce condensation, and we decided to collect this water in a tank: the four Climate Wizard installed work with condensating water from the Air Handling Units, so our Indirect Evaporative Coolers are almost water neutral.”

Deepak Bist, Head Projects and Technical Support at Huhtamaki-UAE

Moreover, this water is particularly clean and pure, being the result of condensation: this increase Climate Wizards’ life, which also require less maintenance.

The Climate Wizard installation gets bigger

Huhtamaki-UAE Management was so satisfied about the Climate Wizard installation and the benefits that this system has brought to them, that they decided to install more units in their Ras Al Khaimah (UAE) plant.

“Working conditions in a hot environment like the one in the United Arab Emirates can be challenging: to improve working morale and operators wellness, we need to ensure that an air cooling system is in place. After having tried Climate Wizard as a pre-cooling solution in our Jebel Ali plant, we decided to have the same installation in our Ras Al Khaimah plant. Now we have 18 Climate Wizard installed in stand alone application to cool one entire process line and 10 units combined with Air Handling Units to pre-cool the air and reduce power consumption (and consequently to reduce running costs).”

Deepak Bist, Head Projects and Technical Support at Huhtamaki-UAE

Climate Wizard solution

Climate Wizard indirect evaporative air conditioner uses a hyper-efficient counter-flow heat exchanger to cool the air. Not adding moisture to the air, it is particularly suitable for humid climates. Climate Wizard’s cooling performance can rival that of refrigerated systems, using up to 80% less energy. That is not only great for reducing power bills, it’s also great for the environment, especially because this system does not use chemical refrigerants to cool the air. Furthermore, using 100% fresh air from outside, Climate Wizard’s performances and cost-saving capabilities actually increase, when the heat is at its highest, in complete contrast with refrigerated systems, which rely on recirculating the air inside the building. Morevoer, when used in Pre-cooling mode, it reduces power consumption of Air Handling Units, to reduce power bills, especially in extremely hot climates (e.g. UAE).

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