FWG Food Application Brochure

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    Air Management for Food Applications

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    Specialised solutions to meet thechallenging requirements of foodproduction, storage and preparation

    Air quality has a direct impact on quality of food production, with the control of airborneparticles, temperature and humidity all being key factors in the creation of a safe environment.

    Great care must be taken to limit the risks to products from airborne contamination.

    Infectious pathogens (e.g. salmonella), toxigenic pathogens (e.g. staphylococcus) andspoilage micro-organisms (e.g. yeast) can all decrease the shelf life of food.Areas of particular concern include undesirablefermentation, aroma development, foodpoisoning and toxi-infections.

    The air system can also play an important role in protecting people from infection in

    their working environment. In addition to the control of airborne contamination, the temperature, humidity and air distributionare all key variables.

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    The food industry is a complex application, because it usually com-

    bines strict hygiene levels with low temperatures. With experience

    from numerous installations in facilities for food production, storage

    and preparation, Flkt Woods is the safe choice for air management

    systems. Our solutions provide ultimate function for the speci c

    demands, whilst meeting the highest standards of energy ef ciency

    to deliver low life-cycle costs for the entire building.

    HVAC systems havea major impact on:

    Contamination ofproducts

    Shelf life of products

    Odours

    Employees health

    Flkt Woods solution:

    Hygienic components

    Easy to disinfect

    Good ltration

    Reduced energyconsumption

    Speci c demandsWhere your building has speci c demands, Flkt Woods has dedicatedsolutions. Our product portfolio includes equipment and systems that meetthe challenging requirements for air cleaning, leakage standards and infectioncontrol. Effective HVAC systems provide a comfortable environment,including temperature, air quality, humidity, odour and noise. It thereforeaffects not only the conditions of the staff, it also facilitates good conditionsfor the preparation and manufacturing of high quality food.

    Cleaning and maintenance

    Maintenance operations such as cleaning are always a major issue with any plant, mostly becauseof functionality issues. Within the food sector requirements are even higher due to the stringenthygienic demands. Every component within our HVAC systems has been designed to facilitatevisual inspection, along with easy and effective cleanability.

    Certi cates and standardsOur systems have been designed and developed in accordance with the moststringent Hygiene standards in Europe. As an example, our eQ Plus AHUreceived the ILH certi cate delivered by the German Institute for Hygienic Air.Flkt Woods AHUs are well designed according to the German standard VDI6022 and the Swiss SWKI Richtlinie VA104-04 (04/2006). This guarantees that maintenancewill be easy and effective and that the materials used are microbiologically inert. We also striveto extend the use of recyclable materials and operate in accordance with ISO 14001.

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    Flkt Woods is not only an experienced HVAC systems integrator.

    We also produce many of the components ourselves. That puts us

    in the unique position where our systematic demands can be closely

    met by component features, and component development is always

    done with the functionality of the entire system in mind.

    Products you can depend on

    Terminal diffuser with absolute ltration, DIF P and K These systems have a double function, passing the air through Absolute Filters beforedistributing it through carefully selected Air Terminals to provide optimal ow patterns.

    Exhaust for critical environment, DEC A and SGrilles designed speci cally for controlled contamination environments. They are easyto clean, perfectly planed and maintenance friendly.

    Dirivent Air Distribution SystemDirivent is an air distribution system capable of moving large volumes of air over long distanceswithout the need for extensive duct installations.It consists of a small bore duct system with jetnozzles to direct the air. Supply air from the airtreatment system is controlled and directedthrough strategically placed jet nozzles, makingDirivent particularly attractive for ventilation andheating purposes. The system can also be usedfor cooling. Dirivent provides full control overtemperature and air ow in all types of premises

    with ceiling heights above 4 meters and up to 36 meters. Strati-cation, which would otherwise increase the overall heat loss and

    create cold draughts in working areas, is prevented.

    Activent Activent is a ventilation system for supply-ing and distributing air. Small air jets fromthe ducts mix with room air through induc-tion. Low temperature air can be deliveredinto the space without causing draughts.

    Displacement DiffusersDiffusers for displacement air distributioncreate quiet installations with both goodair comfort and high ventilation ef ciency.

    The system also permits economical andeffective air cooling. Flkt Woods has alarge range of displacement air terminaldevices with different forms and capacities.

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    Econet Energy Recovery System The components in Flkt Woods innovative Econet system areconnected together to provide a more reliable and more ef cient

    AHU system. Heat recovery, heating and cooling are integratedinto a common circuit as heating/cooling coils, pumps, valves,

    pipe systems, insulation etc. The result is a shorter and morecompact ventilation unit. This is highly bene cial from an environ-mental point of view because much less energy is used totransport the air through unnecessary components. Furtherdevelopment of the principle of energy recovery has also led toincrease in ef ciency of 50% compared to traditional coil recoverysystems. Econet is patented by Flkt Woods and has been installedin more than 1000 sites in Europe.

    No risk of odour/bacteria transfer Supply and exhaust air units can

    be separated from each other Constantly optimised energy

    recovery Pump with sensors and

    frequency converter Exceptionally low temperature

    requirement for hot water Chilled water can be as high

    as 12C Ideal for use with renewable

    energy resources Can recover cooling in

    summer months Ideal for indirect evaporative

    cooling Low life Cycle Costs (LCC)

    Thermal Wheels with 3 Angstrom Technology EQRS is avery powerful rotary heat exchanger that recovers bothsensible (heat) and latent (moisture) energy. With an ef ciencyof up to 85%, EQRS is one of the most powerful rotors availableon the market today. Our hygroscopic rotor has been speciallydeveloped for operation in contaminated air ows. The rotor

    medium is coated with a highly effective transfer media(3 Angstrom molecular sleeve) that eliminates the transfer of contaminated air, making it ideal for the food industry.

    Specialist AHUs for food applications The food industry is a complex application, because it typicallycombines strict hygiene levels with low temperatures. The FlktWoods CC unit has a high standard speci cation to avoid

    condensation and to guarantee easy maintenance and cleaning.

    The CC range provides : Constant tc Controlled humidity No condensation Washable design

    Panels are painted or instainless steel 304 or 316 L

    Polyurethane insulation Plastic tubes incorporated in

    the panels to give a thermalbridge free unit

    Withdrawablecomponents foreasy service,maintenanceand cleanability

    Polyester bottom doublepolyester bottom with excellentthermal insulation

    Smooth angle for optimumhygienic solution

    Special coilsCu/AI Epoxy Cu/CuHeresite Stainless SteelDip galvanized

    Fin pitch between 2,1and 6 mm

    Fin thickness betweens0,1 and 0,6 mm

    Drain tray in stainless steel Defrosting pin

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    Optimised solutions for safe food production

    For each type of product, a risk assessment shouldbe carried out involving all aspects of production andstorage, in order to highlight the critical control points.

    This assessment should consider all aspects of environmental hygiene, including the risk of potentialcross-contamination from adjacent processes, enablingappropriate decisions to be made regarding pressuredifferentials between spaces.

    A correctly designed air handling system is criticalfor the effective elimination of airborne contamination.

    For each of the intended operating standards (low,

    medium and high risk), an appropriate air supplysystem must be speci ed. This should cover:

    The microbiological quality of air The ability of the system to control air ow direction Temperature Relative humidity Overpressure Consideration must be given to each of these pointsduring the various operating states, including start-up,

    production, cleaning, non-production and maintenance.

    Functions of an air handling system for a high risk area (example: cooked meat preparation)

    System function Production Cleaning Non-production Maintenance Start-up

    Remove particles

    Slow microbial growth byreducing the temperature

    Slow microbial growth byreducing relative humidity

    Prevent ingress of micro-organisms (by overpressure)

    Prevent turbulence

    Personnel comfort

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    Example: Cheese productionChallenges: Air system designed to prevent product contamination Dehumidi cation of cheese making process Washable AHU to limit the risk of contamination Constant T C of air (typically 3 C) Corrosion from lactic acid

    Recommended products and systems:CC AHU Coil: Cooling coil with chilled water (0/5C with 30% propylene glycol)

    Large n pitch (6mm) to reduce risk of freezing Stainless Steel tube SS 304 (to avoid corrosion from lactic acid)Dehumidi cation: Via controlled condensationCasing: Cold-bridge-free AHU with 75mm of PU foam

    (no external condensation) All panels in stainless steel 304 L Undertray in stainless steel 304 L,

    fully welded for optimum washabilityFiltration: HEPA Filtration H13, with fully-welded airtight frame

    Diffusion Laminar air ow with HEPA ltration for critical areas Displacement diffusers

    Example: Cooked meats

    Challenges Air system designed to prevent product contamination Constant T C of air (typically 3 C) Washable AHU to limit the risk of contamination

    Zero condensation in technical areas Low fresh air volume (about 10%)

    Recommended products and systems:CC AHU Coil: Cooling coil with chilled water (0/5C with 30% propylene glycol) Large n pitch (6mm) to reduce risk of freezingCasing: Cold-bridge-free AHU with 75mm of PU foam Undertray in polyester: excellent thermal insulation with

    no sharp corners, allowing easy-cleaningEnergy recovery: Econet high-ef ciency heat recoveryFiltration: F9 or H10

    Diffusion Laminar air ow with HEPA ltration for critical areas Displacement diffusers

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    Example: Sweet production(inc. candies or chocolate glazing)

    Challenges: Control of humidity Washable AHU to limit the risk of contamination

    Constant T C of air (typically 10 C)

    Recommended products and systems:CC AHU Dehumidi cation: Via absorption with desiccant wheel

    (better ef ciency - weight of water about 2g/kg of air)Casing: Cold-bridge-free AHU with 75mm of PU foam (no external condensation) Undertray in stainless steel 304 L, fully welded for optimum washability

    Diffusion: Displacement diffusers

    Example: Low risk areas

    Challenges: In areas without speci c hygiene require-

    ments, the emphasis switches to one of cost and energy ef ciency. Such areas

    might include administration of ces,logistic areas etc.

    Recommended products and systems:eQ AHU Modular design and highly ef cient.

    Automated manufacturing provide costeffective solutions.

    Energy recovery: Thermal wheels

    Diffusion Chilled beams

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    Air system recommendations fordifferent products and processes

    Products/In factory treatment

    Packed without further disinfection Fresh Salad Raw Meat Fish Vegetables

    Packed without further disinfection: Pizzas Prepared salads with cooked ingredients Cheeses

    Processed, packed and preservedto prevent microbial growth: Pickles Marinated sh products

    In pack disinfected or sterilised: Fruit juices Beverages

    Disinfected then packaged or heatprocessed, then clean or aseptic ll: Baked pies Bottled milk Sliced meat Soft drinks

    Packed without further disinfection: Recipe dishes Cooked, sliced meats Pasteurised dairy products Frozen, blanched vegetables,

    to be eaten without further cooking

    Risk

    Low risk

    High Care

    High Risk

    Air system recommendations

    Filtration: G4 F5 Physical separation of working area

    Optional Temperature control Optional Mini 45 changes/hour Optional Control of dust ingress and circulation Hygienic disposal of condensation

    from air system and working area

    Filtration: F5 F9 Physical separation of working area Controlled overpressure Optional Temperature control Humidity control Optional Minimum 45 changes/hour Control of dust ingress and circulation Hygienic disposal of condensation

    from air system and working area

    Filtration: F9 H12 Physical separation of working area Controlled overpressure Temperature control Humidity control Minimum 6 changes/hour Control of dust ingress and circulation Hygienic disposal of condensation

    from air system and working area

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    Selecting the right air management technology providesimpressive scope for cutting energy consumptionand costs. Even in a standard, non-domestic building,68% of a energy needs are typically generated by theneeds of heating, cooling and ventilation, but in a Foodenvironment the opportunities for savings are evengreater. Achieving optimum air conditions consumesenergy, so preserving those conditions and recovering

    the associated energy expended through the processof heating or cooling, is essential.

    Highly ef cient heat and cooling recovery A great deal of energy can be recovered from extractair which can be used to reduce energy costs. WithFlkt Woods systems, it is typically possible to recoveraround 70% of the energy, providing a substantialreduction in the heating or cooling load of the building.

    Further savings can be achieved by recoveringhumidity from the extract air. With the higher ef cienciesnow available from Flkt Woods equipment, the amount

    of cooling energy recovered can be signi cant, andas chillers are often one of the major users of energy

    within a Food factory, any reduction in the chillerload has a dramatic positive effect on savings.

    Moreover, with the right system selection, whendehumidi cation is needed, Flkt Woods can drama-tically reduce not only the cooling demand, but alsothe need for post heating.

    Life Cycle Cost (LCC)

    Flkt Woods has created a model for calculating boththe annual energy consumption and the LCC. FlktWoods selection tool, Acon, can calculate the annualenergy cost and the Life Cycle Cost of Energy forthe selected air handling unit over a pre-determinednumber of years.

    Unlike some less sophisticated models, the Aconmodel will consider all majorenergy consumers, includingfans, pumps, drive equipmentfor heat exchangers, heatersand coolers. It also accurately

    re ects the performance of dif-ferent kind of heat exchangers.

    Saving energy and theenvironment with Flkt Woods

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    Temperature, [C]

    Heating

    Heat recovery

    Cooling

    Cooling recovery

    Heating

    Heat recovery

    Cooling

    Cooling recovery

    Heating

    Heat recovery

    Cooling

    Cooling recovery

    Supply air fan Reheating Supply air fan Reheating Supply air fan Reheating recovery

    Without energy recovery Classic energy recovery at 70% ef ciency

    Energy recovery with Twin Wheels

    Comparing the bene ts of Flkt Woods energy recovery technology Increased ef ciency provides greater energy recovery (pink and light blue areas) and reduced post heatingneeded for dehumidifcation (purple area).

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    Reference projects

    Country End customer Name of project Town Year Products - systems

    Portugal Restaurante Montage Grill Porto 2006 ATD

    Portugal Restaurante Abadia Porto 2008 AHU

    Portugal Cervejaria Portuglia Chiado Lisboa 2008 FAN

    UAE ADEAREST Delmote Foods Dubai 2006 AHUs

    UAE HEAS WILD Flavours ME Dubai 2006 AHUs

    UAE Nestle NIDO Manufacturing facility Dubai 2008 Turnkey project including

    design, engineering,supply, installation andcommissioning & testing

    UK Food Enterprise centre Shrewsbury 2008 AHUs

    UK Marlow Foods Marlow Foods Marlow 2007 AHUs

    UK Gerber Foods Gerber Foods Somerset 2006 AHUs

    UK Kerrygold Kerrygold Stafford 2007 AHUs

    France Fromfoid AHU

    France Sodiaal Yoplait

    France Mondial Frigo

    France Tipiak

    Germany Nestle

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    We Bring Air to Life

    Flkt Woods Group SA 18, avenue Louis Casa, CH-1209 Geneva, SwitzerlandTel. +41 22 309 3800email info@ aktwoods.com www. aktwoods.com

    See global website for internationalsales of ces www. aktwoods.com

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    Flkt Woods is a globalleader in air management.We specialise in the designand manufacture of a widerange of air climate and airmovement solutions. Andour collective experienceis unrivalled.

    Our constant aim is toprovide systems that precisely deliver requiredfunction and performance,as well as maximiseenergy ef ciency.

    Air Handling Units (AHUs)

    Modular, compact and small AHUunits. Designed to ensure optimisa-tion of indoor air quality, operationalperformance and service life.

    Air Terminal Devices and Ducts

    Supply and exhaust diffusers and

    valves for installation on walls, ceilingor oor are all included in our largerange and t all types of applications.

    Chilled Beams

    Active induction beams for ventilation,cooling and heating, and passiveconvection beams for cooling. Forsuspended or ush-mounted ceilinginstallation and multi-service con g-uration. With unique Comfort Controland Flow Pattern Control features.

    Residential ventilation A complete range of products forresidential ventilation. Consists of ventilation units, exhaust air fans andcooker hoods designed to optimiseindoor comfort and save energy.

    Energy recovery Dessicant-based product and systemsthat recover energy, increase ventilationand control humidity.

    Fans

    Advanced axial, centrifugal andboxed fans for general and specialistapplications. Comprehensive rangeincluding high temperature and ATEX compliant options. Engineered forenergy ef ciency and minimised lifecycle cost.

    Chillers

    Air-cooled and water-cooled chillerswith cooling capacity up to 1800kW.Designed to minimise annual energyconsumption in all types of buildings.

    Controls and drives

    Variable speed drives and controlsystems, all tested to ensure totalcompatibility with our products.Specialist team can advise on energysaving and overall system integration.

    Acoustical Products

    A complete line of sound attenuatingproducts, including rectangular andround silencers, Media Free silencers,custom silencers and acousticenclosure panels.

    Solutions for all your air climate and air movement needsFlkt Woods is providing solutions for ventilation and air climate for buildings aswell as fan solutions for Industry and Infrastructure.