Cooling systems for factories are essential in manufacturing environments, helping maintain work efficiency and ensuring employee comfort. Many cooling solutions such as natural air, misting, and Cooling Pad panels have been widely applied. KTG Industrial will summarize the most common cooling solutions for industrial factories today.
What is a cooling system for industrial factories?
A cooling system for industrial factories is a technological solution that helps control temperature and humidity in the workspace, especially in industrial environments such as production factories, warehouses, or factories. This system is also commonly applied in garment factories, shoe factories, and more.
The main goal of this system is to create a cool and comfortable working environment. Some systems can also eliminate dust and harmful gases, helping improve air quality. This, in turn, enhances labor productivity, protects workers’ health, and reduces the impact of high temperatures on machinery, equipment, and production processes.
Cooling systems for factories consist of key components like coolers, ducts (spiral air ducts, elbows), exhaust and intake vents, and supports. Common cooling methods include: natural air, air conditioning systems, industrial fans, misting, thermal insulation spraying, exhaust fans, ceiling fans, water spraying, Cooling Pad panels, and more. Some modern systems integrate energy-saving technologies.
Cooling methods for factories used today
Natural convection cooling solution for factories
The natural convection cooling system is a cooling method that uses temperature and air pressure differences to create natural airflow without mechanical equipment like fans or air conditioners.
- The operating principle of this system is based on two main phenomena:
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- Stack Effect: Hot air, being lighter, rises and escapes through vents or roof openings, while cooler air from outside is drawn in through low vents to replace it.
- Wind Effect: Natural wind outside acts on the vent openings, pushing air inside and creating airflow from high-pressure areas to low-pressure areas.
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- Advantages
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- Energy-saving: By using natural water or air sources, the system operates without consuming much electricity for cooling equipment.
- Environmentally friendly: Reduces greenhouse gas emissions since it does not rely on energy-consuming equipment.
- Cost-effective: The natural convection cooling system operates more efficiently, enhancing performance and saving costs.
- Easy to maintain and operate: With a simplified design and no complex parts like compressors, the system is convenient for maintenance, reducing downtime and improving work efficiency.
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- Applications
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- Industrial factories
- Frozen food processing and beverage production
KTG Industrial applies the natural convection cooling system in its industrial factories and leased factories in industrial zones. This method helps optimize cooling efficiency, reduce operational costs, and contribute to environmental protection, meeting the energy-saving and sustainable development needs of tenants.
Natural air cooling solution for factories
The natural air cooling solution is the simplest and most cost-effective method. It is suitable for small factories with fewer workers.
- Operating principle:
Based on temperature and pressure differences, hot air inside is pushed outside, making room for cool air from outside. The open roof structure enhances the convection effect. - Advantages:
- Easy to install and maintain.
- Low cost and energy-efficient.
- Provides a cool environment with continuous air circulation.
- Utilizes the open roof structure.
- Disadvantages
- Efficiency depends on weather conditions and wind direction.
- Cooling capacity is limited and suitable for low-heat factories.
- Applications
Suitable for small-scale factories such as garment factories, leather, and shoe factories.
Natural cooling solutions suitable for Small-Scale Factories
Cooling solution for factories using air conditioning systems
A more effective solution is using air conditioning systems. This method is suitable for both small and large businesses. However, the initial investment and operational costs are high, so it is important to consider for businesses with limited budgets.
- Operating Principle: It pulls hot, humid air and dust out while providing cool air through cooling coils.
- Advantages:
- Quick cooling, high efficiency.
- Suitable for large factories with many machines.
- Disadvantages:
- High investment and operational costs.
- Some older systems may struggle to adjust the temperature for different areas.
- Applications: Suitable for manufacturing plants, printing workshops, and cold storage systems that require specialized designs.
The most common air conditioning system is the Chiller system. This system is designed with water as the intermediary cooling agent. Water is cooled in an evaporator and then pumped into cooling coils to cool the air.
Advantages
- High efficiency, operates continuously 24/7.
- Suitable for factories with areas over 20,000m², with both cooling and heating functions.
Disadvantages
- High investment costs, consumes a lot of electricity.
- Only suitable for factories with a closed design.
Applications: Pharmaceutical factories, printing workshops, and fiber production.
Cooling Solution for Factories Using Industrial Fans
The use of industrial exhaust fans for cooling is a popular method in industrial zones and factories.
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- Operating Principle: It pulls hot, humid air and dust out of the factory while pushing fresh air inside through the pressure difference.
- Advantages:
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- Easy to move the fans around.
- Good cooling efficiency in necessary areas.
- High durability and stable operation.
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- Disadvantages
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- Limited cooling range.
- High investment and operational costs for large fans.
- Applications: Suitable for factories with high heat emissions like smelting plants, brick factories, boilers, and mechanical processing workshops.
Misting Solutions for Factories
A cooling solution for factories using misting involves high-pressure pumps that push water through nozzles to create a fine mist, helping cool the air inside the factory.
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- Operating Principle: The hot air rises and encounters the cool mist, reducing the temperature in the factory space.
- Advantages
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- High cooling efficiency.
- Reduces dust in the factory.
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- Disadvantages:
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- High humidity can affect product quality.
- Not suitable for food or beverage processing factories.
- Applications: Suitable for factories with high ceilings and heat-emitting operations, such as repair workshops, auto garages, and machinery manufacturing workshops.
Misting is suitable for factories with high ceilings
Thermal Insulation Spraying on Roofs
The thermal insulation solution for factory roofs involves using materials such as thermal insulation paint, reflective aluminum foil, or insulated roofing sheets to limit heat absorption from the outside, helping maintain a cool temperature inside the factory.
- Advantages:
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- Cost-effective cooling solution.
- Can be applied to both large and small factories.
- Can be combined with other methods for improved cooling efficiency.
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- Disadvantages
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- Cooling efficiency is not very high during peak hot days.
- Cannot remove dust and hot air inside the factory.
- Applications: Suitable for metalworking factories, cold storage facilities, food production factories, and electronics assembly plants.
Cooling Factory with Ventilation Fans
A factory cooling solution using ventilation fans combined with natural air helps enhance the cooling effect. Ventilation fans are installed on the walls, creating a pressure difference to draw cool air from outside while hot air escapes through the opposite vents.
- Advantages
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- Cost-effective, more efficient cooling than natural cooling.
- Easy to install and maintain.
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- Disadvantages:
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- Only effective for small factories with minimal machinery and personnel.
- Not suitable for large factories with many heat-producing machines.
- Applications: Suitable for small-scale factories such as woodworking workshops, garment factories, and departments with small spaces and few machines.
Industrial ceiling fans
The cooling solution for factories using large industrial ceiling fans with wingspans from 2.3m to 8m is ideal for creating natural airflow, cooling, and ventilating large spaces. These fans help prevent air stagnation and reduce dust, saving over 80% in operating costs compared to central air conditioning systems.
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- Operating Principle: It pushes hot air and dust outside, allowing for a cleaner, more ventilated atmosphere inside.
- Advantages:
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- Effective cooling in large areas.
- Saves investment and operational costs.
- Creates a ventilated space and reduces dust.
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- Disadvantages:
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- High investment costs for large fans.
- Cooling range is limited if using smaller fans.
- Applications: Suitable for factories with high heat emissions, such as smelting plants, brick factories, and boiler rooms.
Industrial ceiling fans are a very popular solution
Negative Pressure Cooling System
The negative pressure cooling system helps create a cool and efficient working environment for factories, offices, livestock barns, or greenhouses.
- Operating Principle: A fan is placed at one end of the factory to exhaust hot air. Cool air from outside is automatically drawn in through openings like doors or walls, creating a cooling effect due to negative pressure.
- Advantages
- Low investment and operational costs.
- Easy to install and maintain.
- Suitable for large factory spaces.
- Disadvantages:
- Cooling efficiency is not high, and it is difficult to adjust the temperature precisely.
- It can produce significant noise during operation.
- Applications: Suitable for small, enclosed factories.
Roof Water Spraying
The roof water spraying cooling method uses high-pressure water pumps to spray water onto the roof of the factory, helping reduce the temperature of the roof from the outside.
- Advantages:
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- Quickly cools down the factory roof.
- Quick installation and usage.
- Increases the lifespan and durability of the factory roof.
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- Disadvantages:
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- Cooling efficiency is not high.
- Does not help cool the inside of the factory.
- Does not limit dust inside the factory.
- Consumes a lot of water.
- Applications: Roof spraying is suitable for welding workshops, mechanical workshops, or factories with few machines and workers.
The roof water spraying method is commonly used in welding and mechanical workshops
Cooling the Factory with Cooling Pad Panels
The cooling system using Cooling Pad panels is an effective cooling method for hot and dry environments, particularly in mechanical workshops and enclosed areas like greenhouses or animal barns.
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- Operating Principle: It uses waterproof cooling pads, through which hot air from outside is drawn by a fan. When the air comes into contact with the water on the pad, the water evaporates and lowers the air temperature, thereby cooling the space.
- Advantages:
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- High cooling efficiency.
- Filters out dust, making the air cleaner.
- Low investment cost, more economical than other cooling systems such as ducted air conditioning or chiller units.
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- Disadvantages
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- Not suitable for areas requiring strict humidity control (such as medical device production or electronics manufacturing).
- Cooling efficiency only reduces the temperature by 3-5°C compared to the outside air.
- Cooling effect is limited in the corners of the factory.
- Applications: This method is suitable for large factory spaces and areas that do not require precise humidity control, such as mechanical workshops, electronics manufacturing, and agricultural zones.
Principles for Factory Cooling System Layout
To ensure an optimal working environment in the factory, the cooling system layout must adhere to some important principles to optimize efficiency and reduce costs.
- Determine the Wind Direction
Choose a wind intake direction that is open and away from areas with bad odors or high temperatures. Correctly identifying the wind intake direction will help optimize cooling efficiency and ensure a more comfortable working environment.
- Create Airflow Paths Across the Entire Space
Place fans opposite the wind direction to maximize the airflow. The airflow path should be unobstructed to allow for natural fresh air circulation and remove hot, stagnant air.
- Symmetrical Placement of Cooling Pads and Ventilation Fans
Cooling pads should be placed opposite the industrial ventilation fans. This arrangement ensures that hot air is pushed out while cool air is drawn into the factory space.
- Choose the Right Fan Size and Number
Based on the factory area and actual needs, calculate the appropriate number and size of fans to achieve high efficiency.
- Limit Areas Without Airflow Exit
Avoid placing exhaust fans in areas without an air outlet. In limited spaces, use ductwork to direct air upward or to the best ventilation exit.
- Fan Placement and Height
Fans should be placed at a height of 2.5m to 4m to facilitate maintenance and replacement.
- Place Water Pad Frames in the Right Location
Water pad frames should be placed in easily maintainable areas, away from places with bad odors, to ensure air quality.
- Choose the Appropriate Ventilation Method
Natural Ventilation: Properly arrange air intake and exhaust vents to allow for natural airflow. This method is cost-effective but depends on environmental conditions.
Mechanical Ventilation Without Ducting: Use exhaust fans and louvers to improve airflow.
Mechanical Ventilation with Ducting: Direct air through duct systems to distribute airflow evenly across the factory.
Combined Cooling and Ventilation: A popular method with lower costs than air conditioning, helping to cool specific areas where needed.
- Optimize Costs and Energy Efficiency
Factory cooling systems consume less energy than air conditioning systems. For example, for a 1,000 m² area, the electricity cost of a cooling system is only 1/10th that of air conditioning.
- Quick and Efficient Installation
The installation of the cooling system typically takes only 20-30 days, ensuring timely progress and operational efficiency.
Conclusion
There are some popular factory cooling solutions listed above. There are pros and cons in each option; ensuring to apply the most suitable to your business.Properly designing and laying out the cooling system not only brings economic benefits but also ensures an ideal working environment, improving labor productivity and workers’ health. KTG Industrial hopes you have gained useful knowledge from this article.
