What are the types and selection methods of air conditioners for factories? Along with an explanation of their advantages, costs, and improvement methods.

Considering better air conditioning systems in factories is crucial to create a comfortable working environment for employees or to properly control and manage products. There are various types of air conditioning systems for factories. Therefore, to select the most suitable product and system for the installation location, the products being handled, and the problems to be solved by the air conditioning system, this article will explain the types and selection methods of air conditioning systems for factories.

Additionally, it provides information on the advantages, costs, and improvement methods for factory air conditioning systems. Please use this as a reference.

If you are considering installing industrial humidifiers in your factory or other locations, please consult IKEUCHI.

The DRY FOG AirAKI humidifier system uses the AKIMist-E industrial two-fluid humidifier, which can energy-efficiently spray "dry fog" mist that does not wet objects even upon contact.

The single-fluid humidifier system AirULM, which offers even higher energy efficiency, is suitable for high-ceiling work areas.

Furthermore, the AE-T unit allows for the installation of a dry fog system without the need for piping; simply supply air from an air compressor, and you can freely select the areas where humidification is desired.

＜Table of Contents＞

1. Performance and characteristics of air conditioning systems for factories

2. Advantages of installing air conditioning systems for factories

3. Characteristics and costs of each type of air conditioning system for factories

4. How to choose an air conditioning system for factories

5. Problems arising from factory air conditioning systems and improvement methods

6. Conclusion

Performance and characteristics of air conditioning systems for factories

Air conditioning systems for factories offer performance and characteristics not found in general commercial air conditioning systems. For example, the following functions are designed with factory use in mind:

・Efficiently distribute air over wide areas
・High durability
・Can withstand heat generated by machinery within the factory
・Air purification function
・Monitoring and tracking functions
・Interoperability with various equipment

The typical style for factory air conditioning systems is floor-standing, but in some cases, ceiling-mounted commercial air conditioning systems may be installed depending on the installation location.

The cost tends to be higher than general commercial air conditioning systems, but they offer high performance suitable for factory environments.

2. Advantages of installing air conditioning systems for factories

Some of you may be in a situation where "commercial air conditioning systems are installed, but factory air conditioning systems are not" due to installation limitations or costs. Installing factory air conditioning systems can offer several advantages.

（1）Increased Production Efficiency

The adoption of factory air conditioning systems creates a comfortable working environment for employees. As work can be done regardless of the season, it is expected to lead to increased work efficiency and improved production efficiency.

（2）Quality Control of Equipment and Products

The adoption of factory air conditioning systems also benefits factory machinery and handled products.

For example, if the air conditioning system properly controls temperature and humidity, it can prevent problems such as equipment overheating due to machine heat. This is also expected to positively impact the durability and lifespan of the equipment.

Temperature and humidity within a factory can cause changes in product properties or deformation. Maintaining optimal temperature and humidity with a factory air conditioning system helps prevent changes in product properties and deformation, and also provides advantages in quality control.

（3）Employee Health Care

If no air conditioning system is installed, or if an air conditioning system is present but not performing adequately, the indoor temperature will be high. High temperatures within the factory pose various risks, such as heatstroke.

Additionally, proper humidification also helps to lower room temperature. Considering the extremely hot weather in recent years, it can be said that the adoption of factory air conditioning systems is essential for employee health care as well.

3. Characteristics and costs of each type of air conditioning system for factories

Air conditioning systems for factories can be categorized into the following four types based on the scope of temperature and humidity control:

・Spot air conditioning
・Partial air conditioning
・Zoned air conditioning
・Total area air conditioning

Additionally, there are the following types of air conditioning systems for factories, categorized by installation method and location:

・Ceiling cassette type
・Ceiling duct type
・Floor standing type
・Large-scale cooling fan

Below, we will explain the characteristics and cost trends of each type of air conditioning system.

（1）Spot Air Conditioning

Spot air conditioning is a method of air conditioning that specifically directs airflow and humidification to a designated location or equipment to control temperature and humidity.

【Advantages】

・Easily movable
・Can be installed where needed
・Some models allow adjustment of the air outlet position
・Since it provides localized cooling and heating, it is more energy-efficient than whole-area air conditioning
・Less expensive compared to other types of factory air conditioning systems
・Can be installed without construction or system installation work

It features the ability to meet various needs, such as desiring installation near heat-generating equipment, near work areas requiring humidification, or in narrow work areas like conveyor belts.

Spot air conditioning is not suitable for adjusting the temperature or humidity of an entire area, but it can be said to be effective when only specific areas require temperature and humidity control.

Considering the cost and installation burden, it can be said that it is easier to install and implement compared to other types of factory air conditioning systems.

（2）Partial Air Conditioning

Partial air conditioning is a system where air conditioners are installed independently for each designated area, department, or room within a factory. Since each air conditioner operates separately, temperature or humidity can be set and adjusted independently for each area, department, or room.

【Advantages】

・Each air conditioning unit can be adjusted as needed
・Expected to be more energy-efficient than whole-area air conditioning

This system is effective in cases where temperature and humidity requirements differ based on the products handled or the production line, such as in food processing plants and chemical manufacturing plants.

（3）Zoned Air Conditioning

Zoned air conditioning is a system that controls multiple areas with a single air conditioning system.

【Advantages】

・Temperature and humidity can be set separately for each zone
・Air is not supplied to unoccupied areas or areas without production equipment
・Can efficiently exhaust hot air from higher areas
・Good energy efficiency

This is an effective air conditioning system in cases where people are present throughout the factory, or where production equipment requiring temperature control is distributed across various areas.

（4）Total Area Air Conditioning

Total area air conditioning is a system that controls the entire factory with a single air conditioning system.

【Advantages】

・Can create a consistent temperature and humidity environment throughout the entire factory
・Among factory air conditioning systems, it is the largest and can control temperature and humidity over wide areas

Due to its high performance, the cost tends to be higher, but it is suitable for cases where a consistent temperature and humidity environment is required over a wide area, such as in automobile manufacturing plants and product storage warehouses.

（5）Ceiling Cassette Type

This is an air conditioning system installed recessed into the ceiling. Primarily, there are three types: 4-way with four air outlets, 2-way with two air outlets, and 1-way with a single air outlet.

【Advantages】

・Since it is recessed into the ceiling, even after installation, it does not clutter the interior view of the room.

However, dust, general dust, mold, and insects can easily accumulate inside the air conditioner, and dust or general dust can easily clog the air outlets, making it unsuitable for work environments with significant dust scattering.

Additionally, it requires caution regarding issues such as maintenance being relatively cumbersome, potential interference with ceiling lighting fixture locations, and high installation costs.

（6）Ceiling Duct Type

This type involves embedding the indoor unit of the air conditioning system and installing it so that only the air outlets are exposed.

【Advantages】

・Since only the air outlets are exposed, the design of the air conditioning system has little impact on the room's aesthetics.
・Because the direction and position of the air outlets can be adjusted before installation, they can be installed in areas requiring a large volume of airflow, such as areas with heat-generating equipment or areas with many employees.
・Since multiple air outlets can be installed per indoor unit, even if a room or area is divided into sections, air outlets can be installed in each room.

However, since the indoor unit is hidden above the ceiling, maintenance can be difficult. In some cases, it may not be possible to install depending on the factory layout, such as when there are many pipes above the ceiling.

Additionally, because dust and general debris easily accumulate around the air outlets, filter cleaning is necessary, and since the ceiling must be cut for installation, costs tend to be high.

Since operational costs, such as cleaning expenses, tend to be higher, it may not be suitable when prioritizing efficiency and productivity.

（7）Floor Standing Type

This is an air conditioning system installed directly on the floor. It is a suitable option when the ceiling is too high for comprehensive temperature and humidity control, or when installing a ceiling-mounted air conditioning system is difficult.

【Advantages】

・Since air and humidity are supplied from ground level, warmth easily starts from the feet, and heating efficiency is easily improved.
・Can be installed without construction or system installation work.
・Relatively low cost.
・Easy to maintain.

Although it can be installed in environments where dust and general debris are easily generated, it requires floor space or wall space for installation, so sufficient space must be provided.

（8）Large-scale Fans

These generate cool air using the principle of "latent heat of vaporization," which is the heat that water draws from its surroundings as it evaporates.

【Advantages】

・Does not cause condensation.
・Can efficiently cool under high room temperature and low humidity conditions.
・High energy-saving efficiency.
・If it's a model with wheels, it's easily movable.
・Can be installed without construction or system installation work.

However, caution is needed regarding issues such as: cooling efficiency is not achieved if humidity is high or if used in a confined space, and water supply is necessary to generate latent heat of vaporization.

4. How to choose an air conditioning system for factories

Factory air conditioning systems come in various air conditioning styles and installation methods, with differing performance and costs. Below, we will explain the key points for selecting the most suitable air conditioning system for your company's factory.

（1）Installation Location

Each type of factory air conditioning system has different installation methods. You should choose a system suitable for the installation location, considering factors such as the size of the indoor space, ceiling height, and the need for construction or installation work. If multiple units are installed, it is also necessary to consider the space and conditions for the total number of units.

In addition to the physical conditions of the installation location, it is also necessary to consider the following installation environments:

・If it is a place where dust or general dust is easily scattered, choose a unit that allows for easy filter replacement and maintenance.
・Choose a unit where the air outlets are not easily clogged by dust or general dust.
・If it is a place where heat easily accumulates, choose a unit that can control humidity to prevent heatstroke.

（2）Scope to be controlled by air conditioning

Each type of factory air conditioning system has a different controllable range. You should choose a system suitable for the scope of use, whether it's for cooling, heating, or humidifying a specific spot, a room, or a department, or for covering the widest possible area.

It should also be considered that installing separate cooling, heating, or humidifying systems may require separate temperature and humidity control at each installation location. If the service area is wide, and a unit with insufficient capacity is chosen, the desired performance may not be achieved.

（3）Products Handled

Choose a factory air conditioning system suitable for the products being handled.

For example, if handling products affected by temperature and humidity, such as food, choose a unit that can strictly control and manage temperature and humidity. For high-precision equipment, it is important to choose an air conditioning system that does not allow dust or general dust to accumulate inside the unit. Additionally, for printing factories, measures to prevent static electricity should also be considered.

（4）Cost

Factory air conditioning systems involve two types of costs: initial costs, such as the cost of purchasing air conditioning equipment and installation costs, and running costs, which arise from operating the factory air conditioning system, such as monthly electricity bills, maintenance costs, and cleaning costs.

Additionally, unexpected costs may arise, such as for connecting pipes or wiring, and for disposing of old air conditioning systems, so it is necessary to be aware of this.

Users often focus only on initial costs, but running costs should also be considered. If products without energy-saving performance are used, electricity bills may increase, or problems such as low cooling and heating efficiency or poor humidification efficiency may occur.

If you have concerns about choosing a factory air conditioning system, you should consult an expert beforehand, considering both cost-effectiveness and performance.

5. Methods for improving problems arising from factory air conditioning systems

Both before and after the installation of a factory air conditioning system, various problems may arise. Below, we will explain the problems arising from factory air conditioning systems and their improvement methods.

（1）Insufficient budget for purchasing or replacing equipment → Utilize subsidies

If the budget for a factory air conditioning system is insufficient, you can utilize subsidy programs.

In January 2024, the Agency for Natural Resources and Energy announced in the "Energy Saving Support Measures Package under the Reiwa 5th Supplementary Budget" regarding "Energy Saving Subsidies," which support the conversion of air conditioning equipment in factories and buildings, as well as commercial water heaters, to energy-efficient types. The budget for support has been expanded, and new support categories have been established to promote electricity use and fuel switching that leads to carbon reduction.

For example, if you switch to a high-efficiency air conditioning system, you can receive a subsidy of one-third of the cost, with a maximum subsidy limit of 100 million yen.

Applications are scheduled to open around March 2024. However, since the subsidy must be applied for after the actual purchase of the factory air conditioning system, it is important to note that funds for the purchase must be secured beforehand.

To ensure a smooth product selection and application process, it is advisable to start requesting quotes for factory air conditioning systems now.

（2）Poor cooling and heating efficiency → Use various methods such as installing humidifiers to improve efficiency

If the cooling and heating efficiency of the air conditioning system is poor, various problems may arise, such as inability to properly control temperature and humidity, or increased electricity bills.

Try to improve cooling and heating efficiency using the following methods:

・Utilize latent heat of evaporation generated by humidification to lower the temperature.
・Partition areas with plastic curtains to concentrate cold air in specific sections.
・Apply heat-insulating films or heat-reflective paints to prevent heat from outside.
・Install exhaust hoods and ventilation systems near heat sources to dissipate heat and humidity.

【Reference Video】Static electricity prevention measures in factories: A case study of humidification in the circuit board component mounting process | Also helps save air conditioner energy and reduce airborne dust problems

Actual examples show that when humidification was introduced in the circuit board component mounting process, the room temperature decreased by 2-3 degrees Celsius due to the latent heat of evaporation, leading to reduced air conditioner usage and energy savings. Furthermore, it was found to help solve the problem of airborne dust. This demonstrates that humidification not only maintains and enhances production efficiency and quality but also provides a variety of other benefits.

（3）Cannot control humidity → Install equipment to improve efficiency or re-evaluate the air conditioning system

If humidity cannot be properly controlled, it can lead to condensation or easily cause static electricity due to dryness. In cases of condensation, it is recommended to improve ventilation as previously suggested.

In cases of dryness caused by the air conditioning system, some humidification methods may, conversely, cause condensation or affect products. Therefore, it is recommended to install an industrial air conditioning humidification system that can precisely control humidity.

IKEUCHI's "AirAKI" industrial air conditioning humidification system uses "Dry Fog," a mist that does not wet objects even upon contact, to precisely control humidity in large areas or specific locations.

Since it can humidify without affecting products, it can maintain the production environment within the factory at an optimal level. It is effective in preventing dryness caused by air conditioning and preventing static electricity.

6. Summary

This article explained the features and types of air conditioning systems for factories, the benefits of their introduction, and methods for improvement.

Factory air conditioning systems have efficiencies and characteristics not found in commercial air conditioning systems. Their introduction brings various benefits, such as optimizing the working environment within the factory and maintaining the quality of products and equipment.

If problems persist even after introducing a factory air conditioning system, or if other issues such as condensation or dryness occur, it is highly likely that the air conditioning system is not suitable for the factory environment. It is recommended to consult with an expert.

If you are considering installing industrial humidifiers in your factory or other locations, please consult with IKEUCHI.

Our engineers specializing in air conditioning humidification will conduct an on-site survey and propose humidifier selection and installation design from multiple perspectives, tailored to the specific issues and environment of each location.

The AirAKI Dry Fog humidification system uses the AKIMist-E industrial two-fluid humidifier, which can energy-efficiently spray "Dry Fog," a mist that does not wet objects even upon contact.

The AirULM single-fluid humidification system, which offers even higher energy efficiency, is suitable for workspaces with high ceilings.

Furthermore, the AE-T unit allows for Dry Fog system installation without the need for piping; by simply supplying air from an air compressor, the desired humidification area can be freely selected.

References

https://www.dry-fog.com/jp/projects-technology/technical-report/hum-002-cm/