Cooling a factory efficiently is crucial for worker comfort and productivity, but traditional refrigeration-based air conditioning is costly to run and maintain. The most cost-effective solutions start with natural ventilation, progress to mechanical ventilation using energy-efficient EC fans, and for optimal cooling, incorporate evaporative cooling as part of a mechanical system to maintain temperatures below 25°C.
For areas requiring strict temperature and humidity control, such as cleanrooms and sensitive manufacturing spaces, refrigeration-based air conditioning remains the best option.
Natural Ventilation – The Cheapest Option
The simplest and lowest-cost cooling solution is natural ventilation. This involves opening doors, windows, and roof vents to encourage airflow, allowing hot air to escape and cooler external air to enter. Many factories, particularly those with high ceilings and large open spaces, can benefit from this approach.
Advantages of Natural Ventilation
✔ Zero running costs
✔ No mechanical equipment required
✔ Simple to implement
However, this method has limitations. It is dependent on outdoor temperatures and wind conditions, meaning it may not be sufficient during heatwaves or in enclosed factory layouts where airflow is restricted. In such cases, mechanical ventilation is the next step.
Mechanical Ventilation with EC Fans – Efficient & Controlled Cooling
When natural ventilation alone isn’t enough, mechanical ventilation using EC (Electronically Commutated) fans provides a cost-effective way to enhance airflow while keeping energy consumption low. EC fans are highly efficient, using up to 70% less energy than traditional AC fans while offering variable speed control to optimise airflow as needed.
Benefits of EC Fan Ventilation
- Energy Efficient – Up to 70% energy savings compared to AC fans
- Consistent Airflow – Provides reliable cooling regardless of external conditions
- Improved Air Quality – Helps remove heat, humidity, and airborne contaminants
For factories that need a reliable cooling solution without the cost of air conditioning, EC fan-driven mechanical ventilation offers a significant upgrade over passive ventilation while keeping operational costs low.
Evaporative Cooling – Maximum Comfort Below 25°C
For businesses that require consistent cooling and temperature control, evaporative cooling is the most affordable active cooling solution. Unlike traditional air conditioning, which relies on expensive refrigerants and compressors, evaporative cooling uses the natural process of water evaporation to reduce air temperature before distributing it throughout the factory. However, it must be integrated as part of a mechanical ventilation system to function effectively.
Why Choose Evaporative Cooling?
- Low Running Costs – Up to 90% cheaper than air conditioning
- Consistent Temperature Control – Keeps factory spaces below 25°C all year round
- 100% Filtered Fresh Air Circulation – Prevents COâ‚‚ buildup and improves air quality and external air is filtered through the coolers.
- Eco-Friendly – Uses only water and fans, reducing carbon footprint
- Phased Installation – Can be installed gradually, reducing upfront capital expenditure
Evaporative cooling can also be used to spot cool specific areas, allowing businesses to target key workspaces before expanding the system across the entire facility. This makes it a flexible and cost-effective solution for factories looking to improve cooling without large initial investments.
Refrigeration for Tight Temperature & Humidity Control
For smaller areas requiring precise temperature and humidity regulation, such as clean rooms, laboratories, and storage spaces for sensitive materials, refrigeration-based cooling is the best option. Unlike evaporative cooling, refrigeration systems can operate independently of external humidity levels and provide highly stable conditions.
Advantages of Refrigeration-Based Cooling
- Precise Temperature Control – Maintains temperatures consistently below 25°C
- Humidity Regulation – Ideal for clean rooms and sensitive manufacturing environments
- Reliable Cooling – Unaffected by external weather conditions
Although refrigeration is the most energy-intensive option, it is necessary for industries that require strict environmental conditions. In these cases, a combination of zoned cooling—using refrigeration for specific areas while employing evaporative or mechanical ventilation in other spaces—can help balance energy efficiency with operational needs.
The Best Approach: Combining Mechanical Ventilation & Evaporative Cooling
For factories looking to optimise cooling costs while maintaining comfortable temperatures, a tiered approach works best:
- Use natural ventilation when external conditions allow.
- Enhance airflow with EC fans for controlled mechanical ventilation.
- Implement evaporative cooling as part of a mechanical ventilation system to maintain temperatures below 25°C during hotter months.
- Use refrigeration cooling in areas that require precise temperature and humidity control.
By combining mechanical ventilation with EC fans, evaporative cooling, and refrigeration where necessary, UK factories can achieve maximum cooling efficiency at the lowest possible cost. This approach ensures a comfortable working environment without the excessive energy bills associated with air conditioning.
Looking to cool your factory efficiently? Evaporative cooling, integrated with the right mechanical ventilation system, could be the key to maintaining the perfect working conditions year-round. Get in touch with EcoCooling to find out more information.
- Published February 19, 2025
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Emma Beresford
Director at EcoCooling.
Driving the development of sustainable cooling solutions.
An experienced sales and marketing manager, working with SMEs to successfully develop and execute growth strategies. Key achievements have been in the identification and entry strategy for new markets via alignment and reapplication of existing IP/technology to new products and services.
