Evaporative cooling can provide significant temperature relief at a fraction of the cost of mechanical cooling.

Industrial settings - with much exhaust airflow for contaminants and a substantial footprint - can struggle to achieve clean and temperate indoor air conditions without expensive mechanical cooling systems. However, the sheer size of many of these facilities prices that technology out of the possible solution set. On the other end of the cooling option spectrum, HVLS fans tend to move the hot air around, dependent on contact cooling for temperature relief. The moving air from HVLS fans can help employees feel more comfortable but cannot address internal heat gains within a facility nor provide temperature relief. Somewhere between those two options stands evaporative cooling technology, which provides tempered make-up air while also improving indoor air quality with the usage of 100% outdoor air. 
 

Two-Stage Evaporative Cooling Technology Shines in Industrial Facilities

The Cambridge ESC-Series evaporative cooling unit is a semi-custom fabricated air handler that can utilize direct (DEC), indirect (IEC) evaporative cooling, or a combination of both indirect/direct (two-stage) evaporative cooling to meet specific usage and dimensional requirements. In two-stage cooling, the first (indirect) stage uses a patented polymer heat exchanger that separates the ventilation air stream from the vaporizer air stream resulting in full sensible cooling without any added moisture. The second stage of cooling provides additional temperature depression through an adiabatic direct evaporative process. With semi-custom options such as stainless steel construction, energy recovery, fan arrays, special filtration, and additional cooling and heating modules, the Cambridge ESC-Series can be designed to meet the specific requirements of your facility to create a healthy work enviornment that increases productivity and improves employee retention.

Learn More

To learn more about how evaporative cooling works in our manufacturing facility in St. Louis, Missouri, engage with one of our representatives who can bring an applications engineer into the conversation. 

 

 

Evaporative cooling has become the system of choice for many business owners in dry climates, utilized to cool their facility while keeping energy consumption and operational costs in check, especially compared to traditional compressor-based cooling. The sheer size of the commercial and industrial facilities that are effectively tempered by evaporative cooling offers insight to the significant savings that can be realized first by the system’s installation and then its continued optimization.

How Do Evaporative Coolers Work?

To optimize performance, we first have to understand how an evaporative cooling system works. The design is simple, yet complex: provide cool, tempered air by converting warmer, dry air through a series of evaporative processes to draw out the air’s natural heat and inject cooler air into your work space. 

Often compared to “swamp coolers” in the southwestern United States, evaporative cooling units utilize more advanced technology that enable them to serve as viable alternatives to conventional cooling beyond just the Southwest and for larger spaces.

There are direct and indirect technologies available in evaporative cooling, essentially designated by the moisture level in your climate and whether or not additional moisture is desired. These systems may be effectively combined in a two-stage unit, such as the ESC-Series, to add additional cooling as the result of the two processes working together. 

Providing comfortable and healthy working environments

The benefits of evaporative cooling extend well-beyond temperature, especially in terms of improved indoor air quality and its effect on your employee’s health and morale. For example, rather than recycling existing and contaminated air in the building,  the 100% outside air brought in by the evaporative cooling system achieves fresher, cleaner air for the workers inside the facility.

The investment of thermal comfort does more than meet a code standard, it signals to your employees that their leadership team cares for them. It increases employee morale and allows them to continue to work at their full capacities, increasing productivity and lowering turnover rate. You probably wouldn’t want to come to work in a 90-degree building on a hot summer day, so why expect your employees to?

4 Tips for Increasing Unit Efficiency 

Have an evaporative system installed? Let’s make sure you are running optimally.

  1. Perform maintenance on your evaporative cooler routinely. Clean the cooling pads, filters, reservoir, and pump at least once a month during the summer months. Maintaining your system will ensure it is operating at peak performance. 
  2. Evaporative coolers rely on temperature differences between the outside air and the wetted evaporative media. Run it during the warmest time of day to get the most out of your system.
  3. Evaporative media should be damp but not wet or dry.  Periodically ensure water levels are within manufacturer recommendations. 
  4. Building ventilation process loads and temperature conditions can vary. For maximum efficiency, ensure your unit is set to meet minimum ventilation requirements while monitoring building humidity levels so as to provide maximum temperature depression without over saturating the space with moisture. 

Come see for yourself

Cambridge Air Solutions Tours are available to answer any questions you may have about cooling your facility. Schedule a tour today to see our own evaporative cooling unit in action at our manufacturing facility and see how it provides cooler air to our facility in the St. Louis summers.

A safe and healthy work environment benefits everyone committed to success. 

The ESC-Series evaporative cooling unit is a semi-custom fabricated air handler that can utilize direct (DEC), indirect (IEC) evaporative cooling, or a combination of both indirect/direct (2-Stage) evaporative cooling to meet specific usage and dimensional requirements. Heating options are also available. The evaporative cooling unit uses 100% outside air to provide tempered make-up air and building cooling. The ESC-Series unit is designed for industrial, commercial, and institutional buildings needing better indoor air quality without the equipment or operating costs associated with mechanical cooling.

The ESC-Series evaporative cooling unit is a semi-custom fabricated air handler that can utilize direct (DEC), indirect (IEC) evaporative cooling, or a combination of both indirect/direct (2-Stage) evaporative cooling to meet specific usage and dimensional requirements. Heating options are also available. 

In this video produced for ASHRAE Journal, our Director of Engineering Dave Binz showcases the ESC-Series two-stage evaporative cooling unit installed in our facility in Chesterfield, MO. 

To learn more about this technology, visit the ESC-Series product page on our site or contact your local Cambridge Air Solutions representative.

To read our previous blog on why we decided it was time to invest in our facility, click here.

This technical blog was written by Randy Niederer, Director of Marketing at Cambridge Air Solutions.
 

As a manufacturer of industrial HVAC equipment, we know quite a bit about the problems that poor indoor air quality within your facility can have on your employees during hot summer months. Trying to achieve temperature relief within your facility when it is 100° F outside, and even hotter inside, requires more than opening your dock doors and pulling hot air through your facility while running HVLS fans. For most facilities, including ours, the equipment that is running inside the facility provides additional heat gain that can drive indoor temperatures well above the 100° F outside air temperature. When this happens within the facility your productivity, quality and even safety may be affected. Your ability to retain quality employees can suffer as well as your ability to hire new talent can be difficult as well.

Our “Enriching Lives” brand promise is something that we take seriously and strive to provide to all those that we interact with on a daily basis. You know the old saying “Talk the Talk, Walk the Walk?” Well, it dawned on us that we were telling our customers that they should be providing healthy working environments for their hard working people when in reality we weren’t doing it ourselves. How could we expect our customers to take us seriously about IAQ if we didn’t? That’s when we decided to take our own advice and install our ESC two-stage evaporative cooling solution in our own facilities in an effort to provide temperature relief for our manufacturing employees during the hot St. Louis summer months.

What we hope to achieve with our new ESC Two-Stage Evaporative Unit investment
By installing our largest ESC 2-stage evaporative unit in our existing facility in Chesterfield, MO and our new facility in Wentzville, MO we can now provide temperature relief for the team members in our manufacturing facilities. The goal will be to decrease the temperature within our manufacturing environments on the hottest days of summer from what use to be an internal temperature of >100° F to a more reasonable working environment of < 85° F. Keep in mind that those 100° F days only happen about 14 days throughout the summer in St. Louis so we should have excellent IAQ throughout the hottest 90 days of summer.

The process to get the ESC-Series unit installed
The process that we went through to install the unit at our facility is no different than what any other facility would go through. We had to conduct a facility review and analysis and then a system design to provide us with the needed temperature relief required for our buildings. We then had to fabricate the custom HVAC solution needed to meet our requirements and specifications, and finally, we worked with a local HVAC contractor to successfully complete the installs. Due to the size of the unit on our Chesterfield facility it required a crane to lift the unit into place. 

Here is a quick time lapse video of the install.

See it for yourself.
If you want to see how well the technology works check out our website this coming spring. We will have a live webcam/page showing how the technology is working. We will have the actual outdoor temperatures, the discharge temperature of the unit and the indoor facility temperature real-time on our website. All in an effort to show that the technology works even in a hot - high humidity climate as St. Louis, MO. You know what they say, "The proof is in the pudding."

At the end of the day we focus on helping leaders in warehouse and manufacturing create healthy working environments for hard working people. If you would like to learn more about how we can help you achieve this goal join us for a virtual or in-person tour where we will talk about our evaporative platform that is creating a better working environment right here at our own facility.

Cambridge Air Solutions manufacturers evaporating coolers. Munters CELdek media is utilized in many of these coolers. Proper care of the media is a key element for maintaining safe, effective and efficient operation of the evaporative cooler. 

Engineering Bulletin MB-SCP-205 Controlling Scale and Dirt in Evaporative Pads

Munters has published Engineering Bulletin MB-SCP-205 Controlling Scale and Dirt in Evaporative Pads.

This bulletin covers topics including:

  1. Proper water distribution 
  2. On-off cycling of the pads 
  3. Common scale forming minerals 
  4. A quick reference chart showing stable water with respect to alkalinity (as CaCO3) and calcium hardness (as CaCO3) 
  5. Cleaning the sump and distribution system 

In addition, important formulae are included for: 

  1. Evaporative cooling 
  2. Water evaporative rate and bleed-off 
  3. Air flow 
     

Air Solutions Bulletin MB-ACC-205 Common Algae Treatment Chemicals

After cleaning and flushing the evaporative cooling system, according to Air Solutions Bulletin MB-SCP-205 Controlling Scale and Dirt in Evaporative Pads, the media can be treated with certain algae control chemicals. Munters has published Air Solutions Bulletin MB-ACC-205 Common Algae Treatment Chemicals.

This bulletin covers topics including the three most common chemical groups: 

  1. Quaternary amines 
  2. Oxidizing biocides 
  3. Copper compounds 

Combinations of these chemicals are found in many swimming pool chemicals and commercial disinfectants. When used continuously, or in too high of concentrations, these products can destroy wood, cellulose and metals. The methodology for calculating disinfectant dosages is shown, along with a table with maximum recommended dosages. 

Approved Chemicals for Cooling Pads

Another bulletin published by Munters is Approved Chemicals for Cooling Pads

This bulletin includes: 

  1. Approved algae control chemicals
  2. Physan 20, as manufactured by Maril Products, Inc.
  3. Triathlon, as manufactured by OHP, Inc. 
  4. Green-Shield, as manufactured by Whitmire Research Laboratories 
     

Cleaners and sanitizers 

  1. Aqua Max XL, as manufactured by Neogen Corporation
  2. Cool -N- Klean, as manufactured by Ivesco, LLC 
  3. Virocid or CID-20, as manufactured by BVS/CIDLines USA 
MB-ACP-205 Air Solutions Bulletin: Preventing Algae in Evaporative Cooling Pads

Munters has also published Air Solutions Bulletin MB-ACP-205 Preventing Algae in Evaporative Cooling Pads

This bulletin covers topics including: 

  1. Shade the pad and sump 
  2. Allow the pads to dry completely once every 24 hours 
  3. Minimize nutrient contamination Cambridge recommends that these engineering bulletins be considered as a basis for the proper maintenance of evaporative cooling pads.

Want to learn more about putting evaporative cooling in your facility? Find a Cambridge Manufacturing Representative in your area!

Our Director of Engineering Dave Binz describes how the Cambridge team approaches an industrial retrofit process, and the best way to get started getting answers about your project.

Cambridge Air Solutions is offering the two-stage ESC-Series to meet current market demands for custom cooling units in the industrial and commercial sectors. With an airflow range from 2,500 to 56,000 CFM, our evaporative cooling technology delivers a more comfortable working environment at a significant reduction in operating costs when compared to mechanical cooling.

Watch this feature of our Cambridge M-Series Makeup Air units with Evaporative cooling!

To learn more about our makeup air technology, visit our our products page.

In this animation, the technology of a ESC-Series two-stage evaporative cooling unit is showcased.