Applications by Sector
Industrial Warehouse HVAC
Rooftops, AHUs and high-capacity systems for industrial environments
High-capacity HVAC systems for industrial warehouses, distribution centers, factories and storage facilities. Rooftops and AHUs from 100 to 5,000 TR with air flow from 10,000 to 500,000 m³/h. Complete solutions for areas from 1,000 to 100,000 m² with ceiling heights of 6 to 25 meters. Evaporative cooling, conventional air conditioning and hybrid systems for maximum energy efficiency. NR-17 compliance for thermal comfort and LEED certifications for sustainability.
Talk to SpecialistTechnical Specifications
Process Requirements
Climate control for thermal comfort and worker productivity in assembly lines, manufacturing and processing. Particulate control and air renewal for workplace quality.
Temperature control for preservation of stored products, especially electronics, cosmetics, non-perishable foods and pharmaceuticals. Zoning for different product categories.
Climate-controlled environment for order picking, checking and packing operations. Thermal comfort essential for productivity in labor-intensive operations.
Cargo transshipment area with climate control to maintain adequate conditions during loading and unloading operations. High-flow systems to compensate for frequent door opening.
Thermal barrier to minimize outside air infiltration during loading operations. High-speed air curtains (8-12 m/s) for efficient sealing on gates 3 to 5 meters high.
Controlled environment for promotional kit assembly, co-packing and value-added operations. Humidity control to prevent damage to packaging and sensitive products.
Laboratory and inspection area with precise temperature and humidity control for product quality testing and verification.
Comfort climate control for administrative areas, meeting rooms, cafeterias and locker rooms. Independent systems for operation outside production hours.
Precision climate control for IT equipment, servers and automation systems. Redundancy and 24/7 monitoring for continuous operation.
Climate control for equipment and vehicle maintenance workshops. Adequate ventilation for gas and particle removal.
Ventilation and climate control for electric forklift battery charging area. Hydrogen gas exhaust and temperature control for battery lifespan.
Segregated area for storage of products requiring specific temperature and humidity conditions, such as sensitive electronics and chemicals.
Technical Analysis
Challenges of HVAC in Large Industrial Volumes
The HVAC of industrial warehouses presents unique challenges due to large dimensions, high ceilings, variable thermal loads, and the need for energy efficiency. A well-designed project can represent savings of 30-50% in operational costs compared to poorly designed conventional solutions.
Thermal Stratification in High-Ceiling Environments
In warehouses with ceilings above 8 meters, thermal stratification is a critical phenomenon. Hot, less dense air tends to rise and accumulate near the ceiling, while cold air remains at floor level. This can result in:
- Temperature difference of 5-10°C between floor and ceiling
- Wasted energy to cool air that is not in the occupied zone
- Thermal discomfort for workers at different levels
- Condensation on metallic roof structures
Solutions to combat stratification include destratifiers (low-speed ceiling fans), underfloor air distribution (UFAD), and recirculation systems with multi-level capture.
Heat Load Calculation for Warehouses
The correct sizing of the HVAC system requires detailed analysis of all heat load sources:
| Component | Description | Typical % |
|---|---|---|
| Transmission (Envelope) | Heat gain through walls, roof, and floor | 25-40% |
| Solar Radiation | Heat from the sun through tiles and skylights | 15-30% |
| Infiltration | Entry of outside air through doors and cracks | 10-25% |
| Lighting | Heat generated by luminaires | 5-15% |
| Equipment | Machines, forklifts, computers | 10-30% |
| People | Metabolic heat of occupants | 5-15% |
HVAC Technologies for Warehouses
Different technologies can be applied depending on local climatic conditions, precision requirements, and budget:
- Rooftops (Roof Units): Compact equipment installed on the roof, with supply ducts. Capacities from 15 to 150 TR per unit. Ideal for warehouses up to 10,000 m².
- Chillers + AHUs: Centralized chilled water system feeding distributed air handling units. Greater efficiency and flexibility for warehouses over 10,000 m².
- Evaporative Cooling: Uses water evaporation to cool the air. 80% more energy efficient than conventional systems, but limited to dry climates (RH < 60%).
- Free-Cooling: Utilization of outside air when temperature allows. Significant savings during nighttime periods and winter months.
Energy Efficiency in Industrial HVAC
HVAC can represent 30-50% of the energy consumption of an industrial warehouse. Optimization strategies include:
- Thermal insulation: Sandwich panels with PU/PIR reduce thermal load by up to 40%
- Reflective paint: White roofs or those with reflective paint reduce solar absorption by 30-50%
- Natural ventilation: Lanterns and wind exhausters for air renewal without energy cost
- LED lighting: Reduces lighting thermal load by 60-70%
- Automation: Demand-based control based on occupancy and external conditions
- Heat recovery: Utilization of rejected heat for water heating
Sector Challenges
Warehouses of tens of thousands of square meters require high-capacity systems with efficient air distribution. Incorrect sizing results in poorly conditioned areas and energy waste.
High ceiling heights (8-25m) cause hot air accumulation near the ceiling and cold air at floor level. Temperature differences of 5-10°C between levels are common without proper treatment.
Industrial processes, lighting, equipment and occupancy generate thermal loads that vary significantly throughout the day and between shifts. Systems must respond quickly to these variations.
Frequent opening of loading gates causes massive entry of hot/cold outside air. A 4x4m door open for 1 minute can represent entry of 500-1000 m³ of outside air.
Climate control of large volumes can represent 30-50% of total energy consumption. Each percentage point of improvement represents significant savings in large-scale operations.
Industrial processes can generate dust, fumes and odors. The HVAC system must ensure adequate air renewal and filtration for occupant health.
Large equipment can generate high noise levels. Acoustic treatment and selection of quiet equipment are essential for comfort.
Equipment installed at height (rooftops, ducts) requires special planning for safe maintenance. Access must be planned in the design.
Industrial operations frequently expand. The HVAC system must be designed to allow future expansions without major modifications.
Warehouses operating 24/7 or in multiple shifts require systems with high reliability and redundancy to avoid unplanned shutdowns.
Our Solutions
High-capacity rooftop units (15-150 TR) for installation on the warehouse. Compact and economical solution for areas up to 10,000 m². Models with economizer for free-cooling.
View ProductHigh-capacity chilled water plant (100-2,000 TR) for large-scale systems. Superior energy efficiency and flexibility for expansions. N+1 redundancy available.
View ProductAir handling units from 10,000 to 100,000 m³/h for efficient distribution in large volumes. Integrated filtration, heating, cooling and humidification.
View ProductZoned climate control for different warehouse areas. Floor, ceiling and cassette models for installation flexibility. Capacities from 3 to 50 TR.
View ProductClimate control for specific areas such as offices, control rooms and laboratories. Simplified installation without need for chilled water plant.
View ProductHumidity control in storage areas for sensitive products, electronics and hygroscopic materials. Capacities from 5 to 500 kg/h moisture removal.
View ProductThermal barrier at loading and unloading doors. Speeds of 8-15 m/s for efficient sealing on gates up to 6 meters high.
View ProductLow-speed ceiling fans for air mixing and thermal stratification elimination. Up to 30% savings in HVAC energy.
View ProductRegulations and Standards
Benefits for Your Business
Success Case
E-commerce Distribution Center - Extrema/MG
Complete HVAC project for a 65,000 m² distribution center of one of Brazil's largest online retailers. The warehouse has 12-meter ceiling height, 24 loading docks, 25,000 m² picking area, 35,000 m² storage and 5,000 m² offices. The system was designed for 24/7 operation with demand peaks on promotional dates (Black Friday, Christmas). The solution included high-efficiency chillers with free-cooling, high-flow AHUs with energy recovery, destratifiers throughout the area and air curtains on all docks.
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