The challenge: adding cooling to a live, fully-racked distribution centre
Following a successful tender in late 2011, DHL secured the Ferrero Rocher supply chain contract to distribute confectionery stock to UK distribution centres, leasing a 144,000 sq ft warehouse on the first phase of DIRFT (Daventry International Rail Freight Terminal) — a 364-acre logistics park with over 5 million sq ft of warehousing. The building already housed a Jet Environmental heating system, but heating alone was no longer enough.
- Nearly 15,000 pallets of Ferrero Rocher stock had to be held at a precise 15°C (±3°) year-round
- A cooling system was needed to work in parallel with the existing gas-fired heating plant
- The retrofit had to be installed around live high-bay racking, sprinklers and lighting
- Coverage was required across both the racking aisles and dispatch areas
Our solution: a high-velocity induction system for cooling and ventilation
Jet designed, supplied and installed a high-velocity induction system delivering summer ventilation and mechanical cooling across the racking and dispatch areas, working in tandem with the existing heating plant.
- Two internal JET air handling units (fresh & return air) matched to two external air-cooled condensers
- High-level ductwork delivering conditioned air via JET induction nozzles into every racking aisle
- Existing TREND controls integrated with a new JET front-end PC for centralised heating & cooling control
- Free-cooling & heat recovery strategies to minimise energy costs
What we delivered
Precision temperature control
Maintains a consistent 15°C (±3°) across the warehouse, protecting nearly 15,000 pallets of temperature-sensitive confectionery.
Retrofit without disruption
Installed at high level around live high-bay racking, sprinklers and lighting, with nozzle coverage in every aisle and minimal loss of pallet space.
Integrated, efficient controls
Existing TREND controls unified with a new centralised front-end PC, unlocking free-cooling and heat recovery strategies to cut energy costs.
Delivered on schedule
Completed on schedule alongside other contractors, with continuous temperature monitoring available to DHL and Jet's engineers remotely.
Inside the installation
"Jet were very well organised throughout the project, were highly detailed in their planning and preparation and worked well alongside other contractors. They remained flexible for the duration of the installation."
Glyn Mabbut, Project Manager, DHL
Show technical specifications
| Location | DIRFT, Daventry, Northamptonshire |
|---|---|
| Facility type | Two-bay steel portal frame warehouse |
| Floor area | 144,000 sq ft (c. 13,378 m²) |
| Stock capacity | c. 15,000 pallets |
| Heating (existing) | External gas-fired AHU & ducting |
| Cooling (new) | 2× internal JET AHUs, 2× external condensers |
| Air distribution | High-level ductwork & JET induction nozzles |
| Temperature maintained | 15°C (±3°) |
| Controls | TREND, integrated with JET front-end PC |
| Monitoring | On-site & remote by Jet engineers |
From frost protection to multi-zone climate control, our engineers design bespoke HVAC systems that perform. If you have a facility with a similar problem, talk to us about it.
