In the heart of a bustling food processing plant, ensuring the highest standards of safety and efficiency is paramount. This case story explores the measures taken to address a significant concern—Salmonella—in a facility where the intricacies of air handling and make-up air systems play a critical role in maintaining a safe production environment.
Salmonella poses a considerable threat to food safety, and in a food processing plant, the risk of contamination must be mitigated through meticulous design and maintenance of the facility's infrastructure. Effective exhaust systems are essential to control airborne pathogens and ensure the hygiene of the production area.
The plant required a comprehensive exhaust system to support 14 Air Handling Units (AHUs) and make-up air units (MAUs). The solution had to integrate seamlessly with the existing infrastructure while addressing the specific needs of the plant, including effective air circulation and contamination control.
Instead of the conventional vertical roof termination, the project opted for horizontal wall termination. This approach provided several advantages, including easier maintenance access and reduced risk of roof leaks, which could otherwise introduce contaminants into the facility.
The project encompassed a total length of more than 1,700 feet of exhaust, designed to accommodate the specific needs of the plant. The combination of various connector sizes and common duct dimensions allowed for a highly customized solution that addressed both current requirements and potential future expansions.
The plant now has 12 Powerstack chimney exhaust systems, each with 2 inches of insulation and meticulously designed to serve the 14 AHUs and MAUs. The connector IDs for these systems varied in size—from 6 inches to 10 inches—while the common duct size IDs ranged from 16 inches to 20 inches, ensuring optimal air flow and system performance.
To enhance control over the exhaust system, 12 TDF Inline mechanical draft fans controlled by EBC31 Modulating Draft Controls were installed in the common chimney, while 80 SMDs pressure control dampers were integrated—one for each riser. These dampers allowed precise and constant regulation of air flow, contributing to efficient operation and improved air quality throughout the plant.
ENERVEX has played a pivotal role in the design and implementation of the exhaust system. Our company not only crafted the entire duct system but also conducted clash detection to prevent any potential issues during installation. Our expertise ensured that the system would operate seamlessly and meet the plant's stringent safety standards.
Installation Timeline
The installation of the exhaust system will be completed in early 2025. The timeline has included the meticulous planning, coordination, and execution required to integrate the new systems in a new plant.
The installation of advanced EPS2 chimney systems, TDF fans and SMDs dampers will mitigate the risk of Salmonella contamination. The improved air flow and exhaust control ensured that the production areas remained safe and hygienic, protecting both the workers and the food products.
By implementing a well-designed and efficiently regulated exhaust system, the plant experiences enhanced operational efficiency. The ability to precisely control air flow and maintain optimal conditions will contribute to a more stable and productive environment.
The horizontal wall termination approach, combined with advanced system components, reduces maintenance costs and minimizes the risk of costly roof repairs. The efficient design and installation process also ensured that the project stayed within budget and was completed on time.
The case of the food processing plant highlights the importance of innovative solutions and expert design in addressing critical safety concerns. By partnering with ENERVEX and opting for advanced exhaust systems, the plant successfully mitigated the risk of Salmonella contamination while enhancing overall efficiency. This project serves as a testament to the effectiveness of tailored engineering solutions in meeting the unique challenges of the food processing industry.
