Case Studies

Sapphire Textile Mills Limited is one of the biggest textile manufacturers in Pakistan. The machinery used in the various processes implement the most modern technology from Europe, Japan and the United States. The cotton is produced locally, while other types of fibres come from the best harvests from around the world. The company produces a complete offering including yarns, fabrics, home linen (tablecloths, curtains) and knitwear, which are then exported all over the world. As we know, raw fibres show different behaviour as regards their capacity to absorb moisture, and their ability to slide through the machinery is affected by humidity. The right level of humidity allows processing to continue without having to stop the machinery.
Managing Director, Nadeem Abdullah, and executive director of production unit number 5, Shaukat Iqbal, realised over time that the air washer humidification system integrated into the humidification chamber wasn’t able to ensure design requirements in more extreme conditions, despite consuming large amounts of water and electricity. New West Technologies, distributor of CAREL humidification products in Pakistan, specialises in innovative energy saving solutions tailor-made to suit customer requirements. It supplied a complete solution, including design, installation, commissioning and after-sales service. The system now operating features two 1000 l/h ChillBooster cabinets, operating in two stages and ensuring minimum power and water consumption. The design requirements were thus achieved with low fixed running and maintenance costs, to the extent where the executive director, Shaukat Iqbal, decided to replace the existing air washers in all production departments.

The ALBA synchrotron, the biggest scientific centre ever built in Spain, is located in Cerdanyola del Vallès, 20 kilometres from Barcelona. The synchrotron is an electron accelerator that generates very fine beams of X-radiation. These beams, when suitably focused, allow scientists to analyse the atomic and molecular composition of various samples of materials, ranging from proteins to viruses, as well as microelectronic devices and new materials. Due to the heat created by the magnets used to deviate the path of the electron beam around the circumference of the storage ring (268.8 metres), a humidification and cooling system has been developed, made up of six air handling units. The contrast was awarded to Axima Suez (now called COFELY CONTRACTING S.A.U.), one of the leading European groups operating in the fields of air-conditioning and industrial and commercial refrigeration systems. The environment is now air-conditioned by six 18,500 m3/h primary air handling units (AHUs), complete with humidification compartment supplied with two humiFog humidifiers. The supervisory system software, according to the outside conditions, decides whether to activate freecooling with enthalpy control or humidification. The temperature and humidity set points are maintained according to design requirements, as evidenced during the inauguration of the accelerator in March 2010.

Founded in 1988, Stampa Grafica has since grown continually to become an established and recognised business in the graphics industry. Partnerships with leading national and international companies have helped lay the foundations for the development of its corporate philosophy, that is, quality, flexibility and proactiveness. Its products are mainly designed for stores and sales outlets in various different sectors: automobiles, cosmetics, wellness centers and grocery stores, and include cases, displays, brochures and catalogues/booklets. As we know, paper is a hygroscopic material and its dimensions vary significantly depending on the humidity.
The air-conditioning system in the printing facilities must ensure a stable temperature of 20 °C and relative humidity between 50 and 60%. The previous solution with wetted media humidifier incorporated into the air handling unit was not satisfactory, due to insufficiently precise control, high water consumption and high periodical maintenance costs. The solution identified involved using a humidification system made up of a CAREL humiFog adiabatic humidifier with 5 blower units that atomise water directly into the environment. The tangential fan in the blowers generates a flow of air that carries the droplets, assisting evaporation.
The design requirements were thus met with low operating and maintenance overheads, to the extent where the owner, Guido Santi, has recommend this solution for the printing industry.

Parchi del Garda Hotel is a brand-new four-star structure set against the magnificent natural backdrop of Lake Garda, strategically located between the area’s main theme parks. Split into five wings, the hotel offers an enviable lakefront location and has 233 rooms, including 15 suites. The low-consumption solution used for room air-conditioning in the hotel consists of six air handling units (AHUs) with cross-flow heat exchangers, exploiting the principle of indirect evaporative cooling.
Air-conditioning is thus provided using a 35,000 m3/h primary air handling unit installed in the basement for the reception hall, restaurants and one conference room, plus five additional 4,500 m3/h air handling units for the rooms, installed under the roof, each fitted with a humiFog adiabatic atomiser featuring two distribution racks, one for cooling the hotel rooms in summer and the other for humidification in winter.
The primary air introduced into the rooms is constantly kept at 25°C, with integration of direct expansion fan coils that use engine driven heat pumps operating on natural gas. A further five independent AHUs serve the other meeting rooms and use humiFog for humidification in winter. Indirect evaporative cooling in summer delivers cooling capacity of 113 kW with 33 kW of equivalent power savings. All for just 1.15 kW (single-phase) of power consumed by each humiFog appliance.

Tortellificio Dalì SPA is the renowned producer of pasta, tortellini and gnocchi based in Crocetta del Montello (Treviso) – Italy.
Dalí, founded in the early ’70s, took on an industrial dimension in 1986 with the opening of its new facilities and the creation of its brand. Today it is an expanding company, with average annual growth of 10% over the last 10 years, that distributes its products in Italy and abroad (around 40%) and that produces several million kilos annually. This has been made possible by the modern plant and continuous investments in the quality of the products and services provided.
The air-conditioning system includes an air handling unit that, in cooling operation, dries the air, removing up to around 80kg/h of moisture. The humidification system has thus been designed to compensate for this dehumidification of the air, especially in the area where the pasta runs on a conveyor belt and is exposed to the ambient conditions.
Given the size of the facilities, in particular the height of the building, the conveyor belt and the machinery installed, humiFog blower units were chosen, each with a capacity of 16 kg/h. Six units were installed, giving an overall capacity of 96 kg/h. 

BDN Sp. z o.o., Rotogravure Printing House located in Wykroty, near Boles?awiec, is a company that prints newspapers and magazines. The production process, in terms of quality and volumes, is the largest and most advanced in Poland. The facilities cover a surface area of around 195,000 m2, with an effective production area of 68,000m2.
The level of air humidity is a significant factor in the printing industry due to the properties of paper: this is made from cellulose, that is, plant fibres that are intrinsically hygroscopic.
The moisture content of the paper naturally tends towards equilibrium with the ambient relative humidity.
For example, at a temperature of 20 °C, the moisture content may be around 6% by weight at a relative humidity of 40%, which increases to 7% when the relative humidity is 60%. This increase causes variations in the dimensions of the plant fibres and consequently the sheet of paper, which shrinks when the humidity decreases and lengthens when it increases. As a practical example, a sheet of paper measuring two A4 sheets in width becomes 1 mm longer when the humidity increases by 10%.
With over thirty years of experience in the production of humidity control systems, CAREL is the most solid and reliable partner for the printing industry.
The exclusive distributor for the Poland, Alfaco Polska – through Mr Franciszek Klimosz, with in-depth knowledge of the application and experience acquired in the field, provided the support needed to supply the best solution for humidity control in the production process.

CONTINENTAL is the well-known manufacturer of motor vehicle tyres. The factory in Brandys, formerly Siemens VDO Automotive AG, located half an hour from Prague, produces consoles for cars and trucks that, depending on the configuration, houses the radio, satellite navigation system and air-conditioner. It also produces dashboards with the odometer, tachometer, clock and other on-board instruments. Continental is the world’s fifth largest automotive industry supplier.
The highly automated and robotised production process guarantees maximum product quality that, as well as being ensured throughout the production process itself, is also checked at the end by testing all the products manufactured.
The Brandys factory is where the electronic boards are manufactured and the finished products assembled. The main technology used is SMD (surface mounting device): the electronic components are miniaturised and rapidly and precisely positioned on the surface of the printed circuit board.
This is followed by the soldering of the pins on the integrated circuits and the assembly of the other components, such as relays and terminals.
An SMD component may measure just one tenth of the size of a traditional component, for around one quarter of the cost, including assembly.
The level of humidity in the air is a significant factor in the electronics industry, mainly because low humidity increases the probability of electrostatic charges forming, as highlighted by electric arcs. These may damage the delicate electronic circuits, compromising the operation of the finished product. This is why maintaining the optimum humidity level guarantees maximum productivity in the factory. Almost all electronics manufacturing sites implement solutions to guarantee the right humidity level to minimise or even completely eliminate the risk of electrostatic charges forming.
With over thirty years of experience in the production of humidity control systems, CAREL is the most solid and reliable partner for the electronics industry.
CAREL spol. s r.o.– through Mr Jan Šimecek, with in-depth knowledge of the application and experience acquired in the field, provided the support needed to supply the best solution for humidity control and adiabatic cooling in the production process.

Headquarter in London, HSBC is one of the largest banking and financial services organisations in the world.
In Dusseldorf Branch (Germany), during winter time, the outdoor air is very dry so that, increasing its temperature with an heating system, its relative humidity decrease leading the air condition at a very low comfort level. The objective was therefore to maintain a correct level of humidity in the air during the winter months, in order to increase the level of comfort and decrease absences due to seasonal illnesses, thus increasing productivity.
A humiFog humidifier has been installed in the air conditioning equipment. Up to 246 kg/h of water can be sprayed by the humifog using only 1,050 watt, that means only 4.26 W/kg. The sprayed water is supplied by a reverse osmosis treatment system so that the maintenance of the humidifier is strongly reduced. The humiFog pumping station is equipped with a Variable Frequency Driver and a multi stage atomising technology obtaining a wide modulation range: the BMS can require humiFog any flow rate in the range 47 to 246 kg/h. In this way, humiFog will spray exactly and only the quantity of water the BMS is requiring. Precise ambient climate control is obtainable using humiFog humidifier to have a very comfortable air condition.

Nastrificio Victor, a Veneto company that has always focused on the needs and dictates of fashion, in 2002 further consolidated its success by acquiring new markets both in Europe and overseas.
For this purpose, Nastrificio Victor has already purchased new machinery so as to fulfil the requirements of even the most demanding customers.
The company is involved in a process of renovation across the board, both concerning the technical aspects and the more creative side of the business. Automatic air humidity control has been installed in the production area, with the following objectives: a drastic reduction in production downtime due to reduced fragility of the fibres processed when the relative humidity is around 65-70%, adiabatic cooling so as to guarantee absorption of some of the sensible heat generated during the operation of the machinery, a decrease in the amount of dust in the air (caused by the processing of the textile fibres), improving working conditions and reducing maintenance of the filters that trap the excess dust in the air.
humiFog is a humidification system for industrial environments that atomises water at high pressure, generating a very fine and uniform spray that is easily absorbed in the air over a short distance. The installation of the humiFog humidification system combined with the spray blowers has the purpose of automatically controlling the air humidity. By maintaining the humidity at the set point of 65% rH inside the factory, the following advantages have been found: reduction of 40% in downtime due to breakages of the fibres, with consequent increases in productivity, adiabatic absorption of some of the heat generated during the production process, with a reduction in temperature of around 3-4°C, less dust in the environment, with a consequent reduction in maintenance of the machinery and improvement in working conditions for the personnel.

This report describes the functioning of the adiabatic air conditioning system at the platforms of Peñagrande subway station, in Camino de Ganapanes street, Madrid.
We shall therefore describe the elements which make up the system and how they work. The installation of this solution provides more comfort, cooling the environment using water as a source of power, and is considerably more economic than traditional cooling systems (direct expansion) as it consumes less power. Due to the thermo hygrometric conditions of the city centre, the adiabatic humidification/cooling system is very convenient during the summer months, as its power consumption is substantially lower.
In order to obtain these conditions we installed a high-pressure atomization unit, with suitable flow and a stainless steel frame including the nozzles needed to nebulize and cool the air.
The main components of the system are pumping station, water distribution and atomization system (nozzles, solenoid valves, connection pipes and coupling units), water treatment system. A special pump generates high pressure water, which is then atomised through stainless steel nozzles, producing a very fine and uniform mist. The droplets created evaporate spontaneously, consequently humidifying and cooling the air. The sophisticated control system combines the action of an inverter, which controls the pump flow-rate, and a series of solenoid valves that activate only the nozzles required, ensuring the system always operates at the optimum pressure to atomise the water, over a wide range of flow-rates.

To prove the remarkable flexibility of the humiFog system, we illustrate an application realised for Tsimis Printing, a well-known Greek company headquartered one hour drive from Athens, which produces coloured quality packaging (for cosmetics, frozen food, ice creams, snacks etc.) made of aluminium foil for provision products.
The company has always been a pioneer in its particular business segment and was among others the first Greek company to introduce the ISO9002 quality standard several years ago.
The rollers of the printing machinery are working at high temperature to obtain correct treatment of the aluminium which causes a high heat emission in the production area. Consequently, the temperatures reach 40 °C in the summer period causing inadequate working conditions.
This problem is of course increased because of the outside summer temperature that can reach up to 45 °C in the valley, where the factory is located.
To cool the air in the production area is was decided to make two new AHUs for adiabatic cooling and to connect these to the existing duct work.
In each AHU a customised rack with special high pressure nozzles is installed to produce a uniform mist across the entire duct section measuring 2,5m x 2,5m. One 250 kg/h humiFog water supply cabinet is installed outside each AHU.
The two humiFog systems are similar apart from that on AHU is located in the production area while the other one is located outside.
In this way adiabatic cooling replaces a traditional cooling coil, reducing the energy consumption to a minimum. At full capacity the two humiFog systems atomise 500 kg of water in total per hour. For each litre of water absorbed into the air, the energy consumption is no less than 700 W creating a total cooling effect at 350 kW.
After one year of operation the client still expresses entire satisfaction with the two humiFog systems installed. The demineralised water has reduced maintenance to a minimum and still no abnormal operation has been observed.