High-Performance HVAC & BMS for Food Processing Excellence
Maintaining strict temperature and humidity control is critical for food production facilities to ensure product quality, safety, and regulatory compliance. Saudi ProTech, a leading MEP contractor in Saudi Arabia, was awarded the design and build contract for the HVAC & BMS system at Almarai Lusine 4B in Jeddah.
Completed in 2021, this project focused on implementing a high-performance cooling system to maintain precise temperature and humidity levels for various production zones, ensuring energy efficiency, hygiene, and compliance with food industry regulations.
Project Overview
Project Details
- Project Name: Almarai Lusine 4B HVAC & BMS Project
- Location: Jeddah 1, Saudi Arabia
- Year: 2021
- Owner: Almarai
- Project Status: Handed Over
- Scope of Work:
- Design & Build of HVAC System
- Chiller & Air Handling Unit (AHU) Installation
- BMS System Integration for Smart Monitoring & Control
- Water & Air Balancing for Pressure Control
- Testing & Commissioning
Project Objectives
Saudi ProTech was responsible for:
- Designing an HVAC system tailored to the temperature and humidity requirements of food production.
- Ensuring compliance with hygiene standards through the use of food-grade air filtration and UV purification.
- Implementing a smart BMS system for remote monitoring and control.
- Optimizing airflow distribution using spiral double-wall ductwork.
- Conducting water and air balancing to maintain consistent air movement and pressure control.
Project Challenges
- Maintaining strict temperature & humidity control for different food processing zones.
- Ensuring compliance with food industry hygiene regulations through specialized HVAC filtration.
- Implementing an energy-efficient cooling system for cost-effective operations.
- Seamlessly integrating HVAC and BMS systems for centralized control and monitoring.
Scope of Work: HVAC & BMS Implementation
1. HVAC System: Precise Climate Control for Food Processing
The HVAC system was designed to ensure uniform temperature and humidity levels across production areas while maintaining food safety and hygiene standards.
A. Chiller & Cooling System Installation
- Installed 2 high-capacity chillers (400 TR each) for consistent cooling.
- 3 primary and secondary pumps for optimized water flow and pressure regulation.
B. Air Handling & Filtration System
- 6 Air Handling Units (AHUs) & 6 Fan Coil Units (FCUs) to regulate airflow.
- Food-grade filters & UV lamps for air purification and bacterial control.
C. Ductwork & Air Distribution
- Installed spiral double-wall ductwork to ensure even cooling distribution.
- Designed ventilation zoning to separate different production areas.
Key Benefits:
– Stable Temperature Control: Maintains ideal conditions for food production.
– Hygienic Air Quality: Eliminates airborne contaminants and bacteria.
– Energy-Efficient Cooling: Reduces operational costs while maximizing performance.
2. Building Management System (BMS): Smart Automation & Control
A centralized BMS system was installed to provide real-time monitoring and automated control over the HVAC system.
A. BMS System Features
- Automated temperature and humidity adjustments for optimal efficiency.
- Remote monitoring from a central computer room for facility management.
- Fault detection & predictive maintenance alerts to prevent downtime.
Key Benefits:
– Smart Energy Optimization: Reduces unnecessary energy consumption.
– Remote System Control: Allows facility managers to adjust settings easily.
– Improved Maintenance Efficiency: Detects potential issues before failures occur.
3. Water & Air Balancing: Precision Performance Tuning
To ensure optimal system efficiency, Saudi ProTech conducted detailed water and air balancing for:
- Pressure control across production zones to prevent contamination risks.
- Consistent airflow regulation to maintain precise environmental conditions.
- Optimized chiller water flow rates to enhance cooling performance.
Key Benefits:
– Balanced Airflow & Humidity: Ensures stable conditions for food storage and processing.
– Reduced Energy Waste: Optimized water and air flow prevents overcooling or inefficiency.
– Improved Product Quality: Consistent temperature control preserves food integrity.
Testing, Commissioning & Handover
After installation, Saudi ProTech conducted comprehensive testing & commissioning to ensure all systems met food industry standards.
A. HVAC Performance Testing
- Verified chiller efficiency under different operational loads.
- Tested AHU & FCU performance to ensure even air distribution.
B. BMS System Optimization
- Automated temperature & humidity control testing for different production zones.
- Trained facility managers on remote monitoring & fault detection.
– Successfully handed over a fully operational, energy-efficient, and automated HVAC & BMS system to Almarai Lusine 4B.
Key Benefits of the Almarai Lusine 4B Project
1. Advanced Climate Control for Food Production
- Maintains precise temperature and humidity conditions for different zones.
- Optimized cooling ensures product quality and extends shelf life.
2. Hygienic Air Filtration & UV Purification
- Food-grade filters & UV lamps eliminate airborne contaminants.
- Ensures compliance with food safety regulations.
3. Smart Energy-Efficient Cooling
- Chilled water system optimizes energy consumption.
- BMS automation reduces cooling waste and improves efficiency.
4. Seamless Integration & Future Scalability
- Centralized control through BMS enhances system monitoring.
- Designed for future expansions and increased cooling demands.
Conclusion: Setting the Standard for Industrial HVAC & BMS
The Almarai Lusine 4B HVAC & BMS Project showcases Saudi ProTech’s expertise in delivering high-performance, energy-efficient, and compliant climate control solutions for the food industry. Our smart HVAC and BMS integration ensures superior temperature regulation, hygiene, and operational efficiency.
Looking for Expert HVAC & BMS Solutions for Food Manufacturing?
Saudi ProTech specializes in customized cooling, ventilation, and automation solutions for food processing, industrial, and commercial facilities.
📞 Contact us today to discuss how we can enhance your factory’s climate control, energy efficiency, and food safety standards with cutting-edge MEP technology!
