Case Study

Turnkey HVAC System Solution at Confectionery Plant

Overview

Client: Valeo (York site)

Industry: Food manufacturing (confectionery production)

Project Overview: This project involved delivering a turnkey HVAC and cooling system for Valeo’s confectionery production facility in York. Newsome designed, installed, and commissioned a bespoke climate control solution to maintain strict temperature and humidity conditions, supporting efficient production and hygiene compliance.

 

In May 2024, Newsome Ltd was appointed to deliver a comprehensive HVAC system for a new production facility at Valeo’s York site. This turnkey solution was designed to meet stringent temperature and humidity control requirements for a high-performance food processing environment. The Project involves the creation of a new ‘Hoops’ production and packing hall, with provisions for future expansion on a second floor. Newsome was tasked with designing, supplying, installing, and commissioning a bespoke HVAC and cooling system to support production efficiency and hygiene standards in line with the client’s operational and regulatory expectations.

Project Scope and Design Criteria

The project was built around a tightly controlled indoor environment, with the ground floor production hall requiring a consistent ambient temperature of 20°C ±3°C and a relative humidity of 35% ±5%. These conditions had to be continuously monitored and maintained at the return air point to ensure the integrity of food production processes.

The design also incorporated refrigeration for two key process components—cooling coils within a Baker Perkins depositor tunnel, operating at an ethylene glycol solution of -1°C and a flow rate of 23m³/h. These systems were designed for steady-state operation and continuous use during a 24-hour, five-day-per-week schedule.

Additional provisions included future scalability for a Phase 2 HVAC installation on the first floor, low-noise external plant requirements, hygienic construction standards, and easy access for routine maintenance.

HVAC and Cooling System Specification

Newsome selected a floor-mounted, weatherproof Air Handling Unit (AHU) built by Sovereign Air Movement Ltd, installed externally on a ground-level concrete plinth. This configuration eliminated the need for support steelwork and allowed safe, practical access for maintenance teams.

The AHU was designed with:

  • Return and supply air fans
  • Fully modulating dampers to enable free cooling
  • Camfil G4 panel filters and F7 bag filters
  • A cooling coil connected to a dedicated chilled water circuit
  • A steam reheat coil for dehumidification during periods of high ambient humidity
  • A grey Plastisol-coated exterior for durability in outdoor conditions

Air distribution was handled by a system of textile air socks suspended from the soffit, supported by an aluminium track and wire system. Air was returned via a wall-mounted plenum fitted with front-withdrawal G4 panel filters. Supply and return ductwork were insulated and clad in Aluzinc, with all joints fully vapour-sealed to prevent moisture ingress and ensure long-term performance.

Chiller and Pipework Installation

Cooling for both the AHU and the Baker Perkins tunnel was provided by a Mitsubishi air-cooled chiller operating on R454B refrigerant. The chiller, rated at 340kW, was equipped with an integral buffer tank and twin chilled water pumps (duty/standby). Positioned next to the AHU on a dedicated plinth, this unit was sized to handle the tunnel cooling load (2 x 134kW) and the room load (80kW), operating continuously during weekday shifts.

Stainless steel chilled water pipework carried a mono propylene glycol solution through the AHU and into the factory ceiling void, running to the two cooling modules. Newsome incorporated modulating 3-port valves and a full pressurisation system to ensure operational flexibility and system integrity. All chilled water lines were insulated with 30mm phenolic foam, clad in Aluzinc, and labelled to BS1710 standards.

Controls and Integration

To ensure optimal energy performance, the system was configured to allow free cooling when ambient conditions permitted, reducing mechanical cooling demand. All components were integrated into a Siemens-based control system, with scope for future expansion to incorporate additional HVAC systems on the first floor.

Installation and Commissioning

Delivery and positioning of the chiller and AHU were completed using a Hiab-equipped flatbed wagon. Newsome engineers handled all mechanical and electrical installation works, including commissioning of the air handling and chilled water systems. Commissioning procedures included pressure testing of the chilled water system, glycol priming, and setup of all control valves and filtration systems. AHU components including filters, fans, and coils were inspected and performance-tested to ensure compliance with the design brief.

Health, Safety and Quality Assurance

All installation works were undertaken in line with CDM regulations and Valeo site requirements. Newsome prepared detailed RAMS documentation, submitted in advance of works, and adhered to full PPE requirements. Site induction protocols were followed, and all personnel were briefed on environmental and safety procedures. Newsome operates an externally audited Health, Safety, and Environmental Management System, and is accredited under SAFEcontractor and Exor. The project team was supported by external H&S consultants, ensuring all activities met legislative and client-specific standards.

Planned Preventative Maintenance

Newsome included a full PPM package to ensure long-term reliability of the HVAC and cooling equipment. Regular maintenance is key to preserving system efficiency, reducing unplanned downtime, and controlling energy consumption—especially important in a 24/5 manufacturing environment.

Project Outcome

This prestigious project represents a benchmark in delivering precise climate control solutions to the UK food manufacturing sector. The HVAC system supplied by Newsome provides robust, energy-efficient performance with full scalability for future expansion.

This successful delivery reaffirms Newsome’s position as a trusted temperature and humidity control partner to the UK’s industrial and manufacturing sectors. From design and specification through to installation and long-term service support, Newsome remains committed to engineering excellence and client satisfaction.