Client: JCB Requirement: Temprature Reduction within plant Solution: Breezair TVA Evaporative cooling system

The combination of CoSaf Environments technical know-how and Seeley International Europe’s Breezair Evaporative Cooling has provided JCB Transmissions with the solution to a very sticky problem. By specifying six Breezair TVA coolers, CoSaf Environments has reduced temperatures in the company’s Gearbox Plant by over 10°C.

JCB Transmission Ltd in Wrexham, North Wales is responsible for the development, manufacture and marketing of gearboxes, axles and power transmission systems. Founded in 1978 to sell components to JCB, it now employs a workforce of 600 and in 2007 won the Queen's Award To Industry. JCB Transmissions also sells its equipment to other manufactures through a subsidiary company, International Transmissions Ltd.

The Gearbox Plant is a high-density 230,000 sq. ft area, which operates a 24/7 shift system. Part of the factory area has a low-level roof, which trapped the warm area and when combined with heat generated from the machines caused temperatures to reach in excess of 33°C in summer. Despite fans and opening doors the high temperatures caused uncomfortable working conditions for the 300 employees.

Looking for a solution that would provide frequent air changes as well as cooling, Site Services Manager, Barry Stevens, turned to CoSaf Environments, the exclusive UK distributor for the Breezair coolers and a heating, ventilating and air cooling specialists, which had worked with JCB Transmissions for many years. The company conducted an in depth survey of the Gearbox Plant area to ascertain the best method of improving overall thermal comfort.

The six Breezair TBA air coolers were installed on the roof above the low roofed section of the Gearbox Plant with cool air being distributed via ductwork to air diffusers and then into the heat-affected areas to provide temperature relief. Such has been the success of the installation that Barry Stevens is in discussions with CoSaf Environments regarding installing heating and cooling into the other part of the Gearbox Plant.

"It is a vast improvement and we are delighted with the results. As a world-leading manufacturer, we take our environmental responsibilities very seriously", said Barry Stevens. "Breezair has enabled us to provide very effective cooling for our employees without using polluting HCFC emissions and using 80% less energy than if we can installed refrigerative air conditioning."

The Breezair coolers are group-controlled by the Breezair Industrial Wall Control (IWC), which enables the cooling system to be controlled at the touch of a button. The IWC has a smart temperature control algorithm that maintains the indoor temperature to within 0.5 degrees of the set point as well as Humidity Limit control, 7-day time clock and comprehensive fault diagnostics enabling the installation to be quickly serviced.

Breezair coolers contain large high efficiency cooling pads that are kept wet by a pump and water distribution system. Air is drawn through the pads by a powerful fan and is cooled by the evaporative process, providing a constant flow of naturally cooled, fresh air, without any air being recirculated.

The Breezair system is housed in a simple, clean, ultra-modern designed plastic casing specially developed to withstand all weather conditions. The Breezair's state-of-the-art components include an innovative water distribution system, which delivers continuous, balanced water coverage to all the pads. The world-patented system ensures maximum cooling efficiency and minimal maintenance problems.

An innovatively designed, aerodynamic fan provides a constant, even flow of air over the pads to provide a welcome cool breeze with minimal noise and low energy consumption. Other pioneering components include a highly efficient water pump that guarantees constant and reliable cooling when most needed, and a long lasting variable speed motor that gives maximum comfort level control.