Project Details

Project  Background

The client, an international printing group, required that the main Press Halls of their facility be enabled with very close control of the internal environment to facilitate high speed, quality web printing to be undertaken.

It was essential that as the facility operates 24/7, other than Bank holidays, that the installation be undertaken around the ongoing production needs and during weekends and Bank Holidays.

Temperature within the Press Halls needed to be controlled to within a tolerance of +/- 1’C and relative humidity to within  +/- 2.5% of the required set point.

Energy consumption was also a major driver and all of the equipment needed to conform to Class A Energy Rating.

Servistec / Enertec, were awarded the design, supply, installation , control and ongoing maintenance of  the process air management system.

The System

Comprises of 1 No. Carrier Aquasnap 522 kW and 1 No. 305 kW chiller/heat pumps installed external to the facility building. Internally the chilled or heated air is distributed via 12 No. Carrier Holland Airostar air handlers. Each unit being fitted with insulated distribution ductwork to enable even distribution of air within the Press Halls. 150 and 100mm carbon steel, insulated, index pipelines connect the chiller / heat pumps to the internal air handlers. All existing gas fired heating plant was de-commissioned and both heating and cooling of the areas is via the new plant.

Humidification of the areas is by means of a high pressure water injection system delivering accurate amounts of de-mineralised water from high pressure  spray nozzles into the Press Halls.

Servistec / Enertec, in conjunction with Trend Controls, installed a sophisticated Building Management System that enables close control of the areas and gives detailed graphical representation of the system status at a computer head end installed within the companies engineering department.

The system was fully commissioned by Servistec / Enertec and is now fully operational and performing  as per the agreed design parameters. Many of the problems experienced prior to the installation of the new system such as ink register inconsistency and web breaks are now greatly reduced and the production facility can concentrate on delivering a continuous quality printing service to its customers.

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