How Upgrading Natural Air Ventilation Systems Improved Hydro’s Industrial Operations
In high-heat industrial environments, such as metal working facilities, poor or limited natural air ventilation slows production, strains equipment, increases energy costs, and places workers at risk of heat-related illnesses. Many facilities rely on outdated fan systems that require constant maintenance and still don’t address the root problem: trapped heat.
Hydro Extrusions, an aluminum extrusion and fabrication facility located in St. Augustine, FL, is one of those facilities whose fan-based systems were working overtime but were still falling short. Frequent maintenance added strain to the facility’s resources, while heat trapped near the ceiling created a hot, stagnant environment throughout the building.
When temperatures on the shop floor started pushing past 110℉, they knew they needed a new approach that didn’t rely on high-maintenance machinery or temporary fixes. They reached out to Moffitt’s industrial ventilation experts for a solution that would not only lower temperatures on the work floor but also boost productivity, reduce costs, and perform under extreme industrial conditions.
Hydro’s High-Heat Challenge & Moffitt’s Natural Air Ventilation Solution
During the aluminum extrusion process, furnaces reach blistering temperatures of up to 930°F. Without adequate ventilation, this heat accumulates at the ceiling, causing floor-level temperatures to surpass 100°F.
Hydro’s aging powered ventilation system wasn’t keeping up, and their existing fans required frequent service, creating downtime, costs, and unsafe working conditions. The last thing they wanted to do was invest in additional fans or cooling units that would negatively impact their sustainability policy while driving up operational costs. They needed a smarter, lower-maintenance solution to move heat out of the building, and powered systems alone wouldn’t solve the problem.
Moffitt Engineers a Smarter System
Airflow dynamics play a critical role in designing optimal ventilation solutions. With Hydro’s complex heat-producing processes, older infrastructure, and natural air ventilation preference, they required advanced solutions. Moffitt’s sophisticated CFD modeling capabilities allowed us to accurately simulate airflow scenarios based on the building’s structure, internal heat profile, existing infrastructure, and a lot of complicated math. This enabled us to test and compare multiple design options without interrupting Hydro’s workflow.
After several iterations using a variety of natural air ventilation products, we were able to develop the best solution for Hydro’s excessive heat problem:
- Six strategically placed MatrixVent units to promote greater air exchange capacity for high-heat zones, such as over furnaces and extrusion equipment.
- 25 Model RR turbine vents to take advantage of existing roof openings, replacing costly fans while drawing hot air up and out of the building.
- Six wall louvers with adjustable and fully opening louver blades to allow for maximum fresh air intake at the ground level, driving more hot air up and out.
Installation Without Interruption
From design to installation, Hydro required minimal process interruptions. They needed to keep their operations on track, even while their industrial ventilation system was being completely re-engineered. As such, the Moffitt team worked around Hydro’s scheduled downtime to complete the installation process. This was made quicker and less costly by retrofitting the RR turbine vents into the former fan locations, preventing the messy and time-consuming process of cutting new openings.
Immediate and Measurable Results
The impact of Hydro’s upgraded ventilation system was immediately felt throughout the building as average floor-level temperatures dropped by 20℉. Employees reported significantly improved comfort and working conditions as consistent airflow reduced internal temperatures even during peak furnace operation. Without powered fans constantly running or requiring costly repair and maintenance, Hydro and its employees benefit from a quieter, more efficient work environment.
Is Your Facility Fighting Heat with Outdated Equipment?
Moffitt designs natural air ventilation systems that solve the problem at the source. We are passionate about helping industrial facilities improve working conditions and thrive on the challenge of high-heat applications.
Contact us today to learn how we can help improve your industrial operations with custom solutions tailored to your specific requirements.
