With energy efficiency on the minds of most facility managers, those seeking to go green and cut utility costs too often overlook the lowest hanging fruit: HVAC and lighting.
Industrial manufacturers of all stripes fight the same tired, costly battles on that front. High ceilings, open spaces and inefficient light fixtures – common features in so many manufacturing spaces – can push gas and electric use to exorbitant levels. However, using cheaply made floor fans or dimming a bunch of fixtures to save some coin won’t work either – employees must be comfortable, safe and productive, which can be a substantial challenge for cost- and carbon-conscious managers.
Finding a middle ground between energy use and employee comfort can be as simple as hanging a ceiling fan. Big Ass Fans provide plenty of air movement for large industrial spaces and provide year-round energy savings, as well as employee comfort.
Fans aren’t just for summer cooling; many industrial users of Big Ass Fans see their biggest energy savings in colder months.
Hot air pumped into buildings during cold months is typically around 5 percent lighter than the outside air. Because heat rises, temperatures at floor-level are drastically lower than those near the ceiling, a problem made worse in facilities with higher ceilings, poor insulation and constantly opening bay doors.
Meanwhile, heating systems expend tremendous amounts of energy to try to overcome this process, known as thermal stratification. Hot air typically has to “stack” from the ceiling downward until the desired temperature is finally reached at floor level, triggering the thermostat to shut off the heater.
Big Ass Fans push warm air – which too often collects uselessly near high ceilings – to floor level, keeping employees comfortable and productive. These fans can also reduce utility costs by minimizing heater run time or allowing the thermostat set point to stay at a lower temperature.
Example: AMSOIL Inc. needed air destratification in the worst way. During frigid winter months, temperatures at ground-level in the 450,000-sq-ft metal facility were up to 30°F colder than at the ceiling. Not only were employees shivering while they worked, but the company was wasting money pouring heated air into a space that had no effective means of getting that air where it was needed most. To eliminate waste and more evenly heat the space, AMSOIL Inc. installed six 24-ft (7.31-m) and two 14-ft (4.26-m) Big Ass Fans. The fans push hot air down and significantly reduce the temperature differential between ceiling and floor – from 30°F to about 1°F. The company’s gas consumption fell by 35 percent.
To effectively destratify the air in spaces as large as the common manufacturing facility, however, the fans must be large enough to move an immense amount of air throughout open spaces and around obstructions, such as shelving and equipment. A single large fan spinning typically uses much less power than the multiple pedestal or high-speed ceiling fans employees and managers often use for comfort.
Amsoil Inc. with Powerfoil
Every manufacturing space is different, so every layout of fans should be customized for maximum effectiveness. When considering an upgrade to fans, seek out companies like Big Ass Fans that offer the following:
Industrial spaces have to use a lot of energy to get their work done, but they don’t have to waste it. The energy-conscious manufacturer can utilize Big Ass Fans to keep comfort and productivity up while keeping energy costs down.
