Carrier Solutions UK Delivers Tailored HVAC Solutions for Leading High-Quality Car Manufacturer

Project Overview
A major manufacturer of high-quality motor vehicles based in North West, England, recently undertook an extensive building project, creating two key buildings: a manufacturing workshop and a quality control facility. The primary aim was to provide efficient and modern heating, cooling, ventilation and humidity control systems to optimise energy efficiency, lower their carbon footprint, enhance climate control and support manufacturing processes.

Toshiba VRF (Variable Refrigerant Flow) systems were selected by building service consultants BREng Hull Ltd as the core solution for their exceptional energy recovery and adaptability to the unique building layouts. The project spanned 12–14 months, marking a significant upgrade in sustainability and operational efficiency for the facilities.

Challenges
The project presented several technical and logistical challenges:

1. Complex Building Configurations:
   The manufacturing workshop was designed in a square doughnut shape, with ancillary rooms surrounding a central workshop. Meanwhile, the quality control building was a long, rectangular structure spanning two floors. The HVAC systems needed to account for these unique layouts to ensure consistent performance across all spaces.
2. Energy Recovery Requirements:
   Efficient heat recovery was a top priority, particularly in the manufacturing areas where dehumidification processes demanded substantial energy.
3. System Integration:
   Seamlessly integrating VRF systems with existing air handling units and humidification control systems required precise planning to maximise energy reuse.
4. Logistical Constraints:
   Plant locations were confined to specific areas of the buildings, necessitating intricate piping and electrical configurations to ensure all spaces were effectively serviced.

Solutions
The design and implementation team, led by BREng Hull Limited and Ventilation Services (UK) and supported by specialist distributor Cool Designs Ltd (CDL), employed several innovative solutions to address these challenges:

• Customised VRF System Design:
  Toshiba’s three-pipe simultaneous heating and cooling VRF systems were installed to manage temperature variations across different areas. These systems enabled heat transfer between spaces, reducing running costs and carbon emissions.
• Energy Recovery Integration:
  Toshiba VRF systems were paired with advanced air handling units featuring heat recovery capabilities. This design achieved a 78% energy recovery rate by capturing heat from extracted stale air and reusing it to warm incoming fresh air. The unique heat recovery of the VRF allows for harvested heat from either rooms or humidity control units to be utilised within the system, requiring heat.
• Optimised Dehumidification Process:
  Humidification control systems were equipped with cooling and heating coils connected to the VRF system. Excess heat generated during the dehumidification process was reintegrated into the system, reducing energy waste.
• Tailored Distribution Networks:
  Innovative routing solutions, such as high-level piping on the first floor and strategic system placement for each building, ensured optimal performance while minimising disruptions.

Testimonials
“This project was particularly rewarding due to the innovative ways we tackled energy recovery and system efficiency. Toshiba VRF systems proved indispensable in meeting the unique demands of the buildings, enabling us to deliver a solution that significantly reduces energy consumption while ensuring occupant comfort.”

-              Rob Smelt, Consultant, BREng Hull Ltd

“From the outset, this was a technically demanding project due to the layout and performance requirements of both buildings. Working closely with the wider project team, we were able to deliver a VRF-based solution that provided a flexible and future-ready system tailored to the site’s specific needs.”

-              Andrew Gill, Engineer, CDL

Results

This project highlights how thoughtful system design, close collaboration and proven technology can effectively address the specific needs of complex industrial environments. By integrating Toshiba’s VRF systems with air handling and humidification controls, the team achieved a strong energy recovery outcome while accommodating challenging building layouts.

The result is a well-coordinated HVAC solution that supports sustainability goals and provides a useful reference point for similar manufacturing applications. Carrier Solutions UK’s ongoing commitment to delivering tailored, energy-efficient systems that meet the demands of modern industry.