Case Study

Zone-Specific HVAC System for Liverpool-Based International Bakery

Overview

Client: A major international bakery based in Liverpool

Industry: Food Manufacturing

Project Overview: Newsome delivered a zone-specific HVAC design and installation for a Liverpool-based international bakery, improving air quality, temperature, and humidity control across production, oven, and packing areas to support hygiene, efficiency, and compliance.

 

As part of an extensive site-wide improvement initiative at a major international bakery in Liverpool, Newsome was appointed to deliver a complete HVAC design and installation package to meet the site’s updated User Requirement Specification (URS). The project, known internally as “Project Rona,” focused on improving air quality, thermal comfort, and production environment compliance across three core areas within the bakery’s B-Block: the Process Area, the Oven Hall, and the Packing Section.

Project Background

The client, a leading player in the global bakery sector, approached Newsome to provide a bespoke industrial ventilation and air conditioning solution to support ongoing operational upgrades and maintain high hygiene and product quality standards. Previous ventilation infrastructure on-site was either in disrepair or non-existent, presenting significant environmental control challenges within key production zones.

Following an initial site survey and review of the URS, Newsome engineers recommended a segmented HVAC design. Each zone would receive its own independent system, configured to meet specific airflow, temperature, and humidity requirements, while ensuring positive room pressurisation to prevent contamination ingress.

Zone-Specific Requirements and Solutions

Process Area (Ground Floor)

This area previously relied on natural airflow through limited openings and fly screens, with no mechanical ventilation present. To meet the client’s production demands and regulatory expectations, Newsome designed a system to deliver 10,000 m³/hr of fresh air. The target conditions were 24°C ± 3°C and 35% ± 15% RH, maintained at the return air sensor. Positive room pressure was also introduced to help maintain hygiene standards.

A packaged rooftop air conditioner (IC350) using low-GWP R454B refrigerant was selected for this zone. This unit provides 262.62 kW of cooling at nominal conditions and includes EC fans, integrated controls, and filtration up to the G4 standard. The solution balances energy performance, regulatory compliance, and resilience in a high-activity environment. To manage humidity levels post-washdown and prevent condensation or microbial growth, an RLZ-101R industrial desiccant dehumidifier was also installed. Its high-efficiency rotor and integrated EC fan system ensure stable humidity control while allowing for seamless integration with BMS systems.

Oven Hall

The Oven Hall’s original fan units were largely inoperable or ineffective, and the existing system near the 0B/1B oven was due to be decommissioned. The new requirement was 15,000 m³/hr of ventilation, with a target temperature of 25°C ± 3°C and maintained positive pressure. A bespoke Air Handling Unit (AHU) was supplied to serve this area, featuring EC backward-curved fans, ISO coarse filtration, and a full mixing box for fresh and recirculated air. The AHU’s technical design included an SFP of 1.01 and total airflow of 15.55 m³/sec. Noise emissions were also considered, with breakout levels controlled to 56 dB(A) at 3m.

Packing Section

As with the Oven Hall, the Packing Section had failing intake and extraction fans. Newsome recommended a standalone HVAC system delivering 12,000 m³/hr of air, with a target temperature of 25°C ± 3°C and positive pressure to protect packaged product areas. This zone was served by an IC220 packaged rooftop unit, offering 213.4 kW of cooling. The unit, operating on R454B, includes inverter-driven compressors, variable speed fans, and double-skinned insulated panels to ensure optimal indoor air quality and energy efficiency. Sound levels, airflow volumes, and pressure demands were modelled specifically for the spatial layout and operational schedule of the Packing Section.

Environmental Considerations

In line with current F-Gas regulations, Newsome prioritised low-GWP refrigerants across all systems. R454B, with a GWP of 531, offers a 76% reduction compared to R410A and is currently one of the most suitable long-term alternatives for commercial and industrial cooling. The use of R454B across all packaged systems not only future-proofs the installation but also improves efficiency without compromising thermal performance.

Installation Approach

The installation was phased to minimise disruption to ongoing production. Pre-start meetings ensured coordination with site teams, with crane and Hiab access arranged for major equipment positioning. External works, including ductwork bracketry and insulation, were completed first, followed by internal works staged in accordance with client schedules. A coordinated commissioning plan saw all three systems brought online simultaneously. All works were delivered in compliance with CDM regulations and with due consideration to hygiene and safety standards for live food production facilities.

Ongoing Support

Newsome continues to support the site with a comprehensive service and maintenance agreement, ensuring long-term performance of all systems installed. Options for extended warranties, glycol supply, water treatment, and remote BMS integration were included in the scope to maximise reliability and system lifecycle value.

Summary

This project demonstrates Newsome’s capability to deliver complex HVAC solutions within active food manufacturing environments. By adopting a zone-specific approach and applying engineering best practice, the team provided a scalable and compliant solution that supports productivity, hygiene, and energy efficiency goals.

For more information about our bespoke HVAC, cooling and dehumidification solutions for the food and beverage sector, contact our team directly.