Cooling Without Compromise in Plastics Manufacturing

Key Objectives

The Challenge

A-SAFE operates a plastic manufacturing facility with heat-intensive moulding processes that create high localised temperatures. During warmer months, internal heat gains combined with rising external temperatures caused uncomfortable conditions and uneven thermal performance across the factory. Some production areas experienced sustained overheating, while others required effective ventilation, creating a need for a flexible spot-cooling solution capable of responding to varying heat loads throughout the year.

Overhead crane rails limited internal ductwork options, electrical services were required to be routed internally rather than via the roof, and installation needed to be completed with minimal disruption so manufacturing could continue uninterrupted.

The Solution

CPA Engineered Solutions designed and delivered a full turnkey solution which combined Breezair Direct Evaporative Cooling units with EcoPower Hybrid Roof Ventilators to ensure that cooling was targeted where required, while natural or low-energy ventilation could be utilised elsewhere.

The evaporative coolers were strategically deployed to supply high volumes of cooled, filtered fresh air to areas most affected by process-related heat gains. In parallel, roof ventilators were installed to continuously extract rising heat and promote effective air change across the wider facility. This combination ensured that cooling was targeted where it was genuinely required, while natural or low-energy ventilation could be utilised elsewhere.

The hybrid configuration provides significant seasonal flexibility. In milder conditions, the Breezair units operated in ‘free cooling’ mode and the Ecopower units operate in natural or low energy wind assisted ventilation mode, reducing water and energy consumption. During colder months, when cooling is not required, the Ecopower ventilators continue to manage air quality with zero energy input.

The Result

The completed installation delivered a highly efficient, flexible environmental control solution aligned with the realities of plastics manufacturing. A-SAFE reported noticeable improvements in air quality, airflow, and overall working conditions once the system was commissioned, particularly within high heat load production zones. By combining evaporative cooling with hybrid roof ventilation, the system provides year-round performance while minimising energy use.

A-SAFE’s continued willingness to host site visits for prospective customers reflects their confidence in the system and their satisfaction with CPA Engineered Solutions.