Case Study

Delivering a Scalable HVAC Hire Solution for Huel’s Production Facility

Overview

Client: Huel Ltd, UK

Industry: Food Manufacturing / Plant-Based Nutrition

Project Overview: Turnkey HVAC Hire for Summer Cooling Delivered in Summer 2024

Newsome was approached by Huel, a leading UK-based provider of nutritionally complete, plant-based meals and supplements, to supply a high-performance temporary HVAC solution for their facility in Hertfordshire. With rising seasonal temperatures and sensitive production conditions, maintaining stable internal environments was essential to ensure staff wellbeing and consistent process control across the mezzanine-level production areas.

 

Founded in 2015, Huel is a pioneer in the plant-based meal replacement industry. The brand’s rapid growth and direct-to-consumer model have positioned it as a key player in the health-conscious food and beverage market. As demand increases, so too does the need for flexible, dependable climate control to support year-round production.

 

Following initial conversations and a review of the site’s layout and thermal load demands, Newsome engineered a bespoke cooling solution using its hire fleet of packaged chillers and high-capacity vertical air handling units (AHUs). The system has since been successfully installed and is now in continuous operation, helping Huel maintain optimum conditions during periods of high ambient heat.

The client’s initial request was for two air handling units to be positioned on the mezzanine floor. However, based on an assessment of the site’s cooling demand, it was clear that a more robust solution was needed. Newsome identified that reducing the original scope to only two AHU units would reduce available cooling by 33%, and airflow by as much as 50%, potentially leading to inadequate performance during peak heat.

Our recommendation, based on minimum estimated demand of 150 kW cooling capacity, was to supply:

  • 1 x NR-120 packaged chiller providing up to 116.1 kW cooling at nominal conditions
  • 4 x NR-AHU50 vertical air handling units, each capable of delivering 69 kW cooling or 134 kW heating (if required)

This configuration ensured coverage of the entire mezzanine area, improving temperature distribution and maintaining operational stability during the hottest days of the year.

NR-120 Process Chiller

The NR-120 is a high-performance, air-cooled process chiller designed specifically for demanding production environments like Huel’s. It features:

  • Scroll compressors operating on R410A refrigerant
  • Shell and tube evaporator integrated with the buffer tank
  • Built-in circulating pumps and pressure bypass valves
  • SEPR and Ecodesign 2021 compliance
  • Robust outdoor housing and a wide ambient temperature range (down to -10°C, up to +45°C)

The unit’s energy efficiency ratio (EER) of 3.87 and total cooling capacity of over 116 kW make it ideal for dynamic and temperature-sensitive operations such as food production.

NR-AHU50 Vertical Air Handling Units

Each of the four NR-AHU50 units was strategically placed on the mezzanine level to maximise airflow distribution and target heat-prone areas. These compact, floor-standing AHUs are designed for applications where footprint and access are limited but air delivery performance is critical. The EC fans are inverter driven, allowing variable-speed control based on sensor feedback. Each unit was supplied with an integral condensate pump, humidity sensors, and full temperature control, ensuring autonomous operation and minimal ongoing oversight from the Huel engineering team.

Outcome and Performance

The solution has now been in successful operation throughout the early summer period, maintaining a consistent and comfortable working environment for staff and helping to protect product integrity in high ambient conditions.

Despite initial constraints around space and airflow distribution, the combination of a high-capacity chiller and four intelligently deployed AHUs has proven highly effective. By distributing the cooling load across the mezzanine, the system achieved a more stable air temperature profile, even during recent heat spikes exceeding 30°C. The feedback from site has been positive, with reliable performance and energy-efficient operation contributing to both comfort and operational continuity.

Conclusion

This project highlights Newsome’s ability to respond quickly to client needs and deliver tailored HVAC hire solutions for critical food production environments. By leveraging its fleet of modern chillers and air handling units, Newsome was able to ensure Huel’s production processes remained unaffected by rising seasonal temperatures. Whether for short-term hire or long-term temperature control strategies, Newsome continues to support UK manufacturers with industry-leading expertise and equipment. For Huel, this hire project was not just about staying cool—it was about maintaining performance, protecting product quality, and ensuring the wellbeing of their team.

To discuss your temporary or permanent HVAC requirements, contact Newsome today.