Multi-Stage HVAC Project for the Polipak Flexible Packaging Manufacturing Plant
A multi-stage project for Polipak, a leading flexible packaging manufacturer, required the installation of several types of air handling units:
- OPTIMA COMPACT MONOBLOCK frameless air handling units
- OPAL COMPACT air handling units
- OPTIMA air handling units with non-standard dimensions exceeding 3 metres in height, 4 metres in width and 7.5 metres in length
The combined supply airflow of the installed units exceeds 200,000 m³/h.
One of the most distinctive features of this project was the implementation of evaporative (adiabatic) cooling technology, a solution still rarely applied in Poland. The OPTIMA air handling units were equipped with evaporative cooling modules supplied directly with mains water.
Evaporative Cooling Technology
Evaporative (adiabatic) cooling is typically used in regions with hot and dry climates, where low ambient humidity allows the system to achieve maximum cooling efficiency.
The process is based on the evaporation of water from a specially designed cooling media installed inside the air handling unit. The cooling media consists of high-density, porous material arranged in multiple layers to create a network of channels through which water continuously flows. For this project, cellulose evaporative cooling pads were selected.
How Does Evaporative Cooling Work?
Supply air drawn through the air handling unit passes across the wetted cooling media. As the water evaporates, it absorbs heat from the incoming air, reducing its temperature while simultaneously increasing its humidity before it is supplied to the conditioned space.
The water circulation system operates in a closed loop. After passing through the evaporative module, the water returns to the storage tank, where it is recirculated and reused.
Maximum cooling efficiency is achieved through a proprietary control algorithm developed by Clima Gold, which continuously optimizes the operation of the evaporative cooling module according to current operating conditions.
Benefits of Adiabatic Cooling
Air handling units equipped with evaporative cooling technology offer several important advantages.
Environmentally Friendly Operation
The system operates without conventional refrigerants, reducing environmental impact and eliminating the need for refrigerant handling.
High Energy Efficiency
Cooling is achieved through the natural evaporation of water rather than mechanically driven refrigeration, significantly reducing electrical energy consumption and improving overall system efficiency.
Lower Operating Costs
Installation requires only a mains water connection, eliminating refrigeration circuits and reducing both installation costs and long-term expenses associated with refrigerant charging and maintenance.
Simplified Maintenance
Routine maintenance is limited to periodic cleaning of the evaporative cooling media and air filters, together with regular monitoring of the water quality and water level within the storage tank, ensuring reliable and efficient long-term operation.
