ALMARAI LUSINE 4A: HVAC & BMS Design and Build Project in Jeddah, Saudi Arabia
Saudi Arabia’s food industry demands high standards when it comes to environmental control, product preservation, and operational efficiency. At Saudi ProTech, we specialize in delivering cutting-edge HVAC (Heating, Ventilation, and Air Conditioning) and BMS (Building Management System) solutions that cater to these requirements. One of our landmark projects was the ALMARAI LUSINE 4A facility in Jeddah, Saudi Arabia, completed between 2009-2010. This project focused on designing and building a high-performance HVAC system and an advanced BMS to ensure the optimal environmental conditions required for food processing and storage.
In this case study, we will explore the scope of work, technical execution, challenges overcome, and benefits delivered to ALMARAI’s facility through our specialized HVAC and BMS integration services.
Project Overview
About the Project
- Project Name: ALMARAI LUSINE 4A
- Location: Jeddah 1, Saudi Arabia
- Year: 2009-2010
- Owner: ALMARAI
- Project Status: Handed Over
- Scope of Work: Design & Build of HVAC & BMS
Objective of the Project
ALMARAI required a custom-engineered HVAC system that could:
- Ensure precise dry bulb temperature and relative humidity control across different zones.
- Optimize cooling efficiency for food production and storage.
- Meet food safety standards by integrating food-grade air filtration and UV sterilization.
- Enable centralized monitoring and automation through a robust Building Management System (BMS).
Project Challenges
- Designing an HVAC system that maintains strict environmental conditions across multiple production areas.
- Installing food-grade filters and UV lamps to ensure hygiene and air quality compliance.
- Integrating chillers, pumps, AHUs, FCUs, and ductwork into a unified control system.
- Optimizing energy efficiency while maintaining uninterrupted cooling performance.
Scope of Work
HVAC System Design & Installation
1. Custom System Engineering
Our design team worked closely with ALMARAI to develop an HVAC system that aligns with their facility’s food safety requirements.
- Site Assessment & Architectural Plan Integration:
- Evaluated zone-specific cooling loads and air distribution needs.
- Designed the system layout to integrate seamlessly with production processes.
- Energy-Efficient HVAC Modeling:
- Simulated heat loads and optimized ductwork layouts to prevent energy loss.
- Selected high-efficiency equipment to reduce long-term operational costs.
2. Chillers Installation
We installed 5 high-capacity chillers, each with a cooling capacity of 400 TR (Tons of Refrigeration).
- Key Functions:
- Provides reliable, large-scale cooling for food processing areas.
- Ensures temperature consistency to prevent spoilage.
- Benefits:
- Energy-Efficient Cooling: Optimized performance reduces electricity consumption.
- Robust Reliability: Designed for 24/7 operation with minimal maintenance.
3. Pumps & Water Circulation
To ensure efficient heat transfer, we installed 5 pumps designed for continuous operation and low energy consumption.
- Benefits:
- Stable water circulation, preventing cooling disruptions.
- Reduced downtime due to durable, high-efficiency components.
4. Air Handling Units (AHUs) & Fan Coil Units (FCUs)
- 25 AHUs Installed:
- Equipped with food-grade filters and UV lamps for sterile air distribution.
- Designed to regulate temperature and humidity effectively.
- 10 FCUs Installed:
- Installed in critical areas requiring localized cooling.
- Features food-grade filters to maintain hygiene standards.
- Benefits:
- Improved Air Quality: Eliminates airborne contaminants.
- Enhanced Humidity Control: Prevents excess moisture buildup in food processing zones.
5. Spiral Double-Wall Ductwork
We implemented a spiral double-wall duct system to ensure efficient and insulated air distribution.
- Key Benefits:
- Thermal Efficiency: Reduces energy loss from air handling.
- Durability: Designed to withstand industrial conditions.
- Consistent Airflow: Ensures uniform cooling across all zones.
Building Management System (BMS) Integration
A state-of-the-art Building Management System (BMS) was implemented to ensure centralized monitoring and automation of the HVAC system.
1. BMS Setup & Integration
- Centralized Control Room: Installed an advanced BMS interface for real-time HVAC management.
- Automated Monitoring & Alerts: Sensors detect deviations in temperature or humidity.
- Smart Adjustments: Automated settings optimize energy efficiency.
2. Benefits of BMS Implementation
- Optimized Energy Consumption: Reduced power wastage through real-time adjustments.
- Early Fault Detection: Predictive maintenance alerts prevent costly breakdowns.
- Improved Operational Efficiency: Remote control capabilities allow immediate system tuning.
Key Benefits of the ALMARAI LUSINE 4A HVAC & BMS Solution
1. Precision Environmental Control
- Ensured optimal dry bulb temperature & humidity levels across different facility zones.
- Maintained strict air quality standards with UV-treated air filtration.
2. Food Safety & Hygiene Compliance
- Food-grade filters & UV sterilization eliminate airborne contaminants.
- Prevented moisture-related contamination in food processing areas.
3. Energy Efficiency & Cost Savings
- High-efficiency chillers & pumps reduced operational costs.
- BMS automation optimized energy usage without sacrificing performance.
4. Reliability & Centralized Control
- Real-time monitoring & alerts allowed proactive system management.
- Automated fault detection minimized downtime and improved system longevity.
Project Completion & Future Impact
The successful handover of ALMARAI LUSINE 4A’s HVAC & BMS project positioned the facility at the forefront of industrial cooling technology. Saudi ProTech’s expertise in designing, installing, and integrating advanced HVAC & BMS solutions ensured that ALMARAI’s food production plant met the highest energy efficiency, operational reliability, and food safety standards.
Looking Ahead
- Ongoing Performance Monitoring: ALMARAI’s facility continues to benefit from predictive maintenance tools built into the BMS.
- Scalability for Future Expansion: The HVAC & BMS framework allows for seamless upgrades as production demand increases.
Conclusion: A Benchmark in Food Industry HVAC & BMS
The ALMARAI LUSINE 4A HVAC & BMS project in Jeddah is a prime example of how specialized engineering, innovative technology, and meticulous execution can create a state-of-the-art environmental control system for food production.
Partner with Saudi ProTech
If you’re looking for a trusted HVAC & BMS provider in Saudi Arabia, Saudi ProTech offers tailor-made solutions to ensure energy efficiency, regulatory compliance, and long-term reliability.
📞 Contact us today to discuss how we can enhance your facility with cutting-edge HVAC and automation solutions.
