Breezair provides JCB transmissions with a green solution to high factory temperatures

JCB Transmissions in Wrexham, North Wales is responsible for the development, manufacture and marketing of gearboxes, axles and power transmission systems. Founded in 1978 to sell components to JCB, it now employs a workforce of 550. JCB Transmissions also sells its equipment to other manufacturers through a subsidiary company, International Transmissions Limited, and in 2007 ITL won the Queen’s Award To Industry.

The Gearbox Plant is a high-density 230,000 sq. ft area, which operates a 24/7 shift system. Part of the factory area has a low-level roof, which trapped the warm area and when combined with heat generated from the machines caused temperatures to reach in excess of 33°C in summer.

Looking for a solution that would provide frequent air changes as well as cooling, Site Services Manager, Barry Stevens, turned to CoSaf Environments, the exclusive UK distributor for the Breezair coolers and a heating, ventilating and air cooling specialist, who had worked with JCB Transmissions for many years. The company conducted a thorough on-site survey of the Gearbox Plant area to ascertain the best method of improving overall thermal comfort.

Following the survey an evaporative cooling system was designed and six Breezair TBA air coolers were installed on the roof above the low roofed section of the Gearbox Plant with cool air being distributed via ductwork to air diffusers and then into the heat-affected areas to provide temperature relief. Such has been the success of the installation that Barry Stevens is now in discussion with CoSaf Environments about installing heating and cooling into the other part of the Gearbox Plant.

“Breezair has enabled us to provide very effective cooling for our employees without using equipment with polluting HCFC gases and using 80% less energy than we would have used had we installed refrigerative air conditioning.”

The Breezair coolers are group-controlled by a single Breezair Industrial Wall Control (IWC), which enables the whole cooling system to be controlled at the touch of a button. The IWC has a smart temperature control algorithm that maintains the indoor temperature to within 0.5 degrees of the set point as well as Humidity Limit control, 7-day time clock and comprehensive fault diagnostics enabling the installation to be quickly serviced.

Breezair coolers contain large high efficiency cooling pads that are kept wet by a pump and water distribution system. Air is drawn through the pads by a powerful fan and is cooled by the evaporative process, providing a constant flow of naturally cooled, fresh air, without any air being recirculated.

The Breezair system is housed in a simple, clean, ultra-modern designed plastic casing specially developed to withstand all weather conditions. The Breezair's state-of-the-art components include an innovative water distribution system, which delivers continuous, balanced water coverage to all the pads. The world-patented system ensures maximum cooling efficiency and minimal maintenance problems.

An innovatively designed, aerodynamic fan provides a constant, even flow of air over the pads to provide a welcome cool breeze with minimal noise and low energy consumption. Other pioneering components include a highly efficient water pump that guarantees constant and reliable cooling when most needed, and a long lasting variable speed motor that gives maximum comfort level control.