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繁體中文Reducing HVAC Fan Energy in a Sports Beverage Plant: A Practical Upgrade Story
07/16/2026Energy projects sometimes focus on chillers while leaving air movement unchanged. In many facilities, however, supply and exhaust fans operate for long periods and continue at high speed even when demand has fallen. A retrofit delivered by AISA PACIFIC SHENGRUI LIMITED for a large sports beverage manufacturing company illustrates how better fan selection and control can address this hidden load.
The first step was not to select a new fan. It was to understand how the existing equipment was being used. Beverage plants often run ventilation equipment for long hours, while process zones have different temperature, humidity, and air-quality needs. Large-airflow, high-pressure belt-driven systems accumulate both energy and maintenance costs. The review therefore included filters, dampers, leakage paths, duct transitions, operating schedules, and the difference between design demand and current demand.
Available project information showed that The project record lists six fan duties ranging from approximately 11,000 to 74,000 m³/h at about 1,100 to 1,200 Pa. Original power ranged from roughly 7.5 to 45 kW, while post-retrofit operating power ranged from about 5.3 to 36.5 kW. Recorded savings were approximately 18.89% to 39.09%. The source estimate shows annual electricity savings of about RMB 175,988.4 and annual maintenance savings of about RMB 22,000, for a combined estimate of roughly RMB 197,988.4. These figures provided a traceable engineering reference, while final selection remained subject to measurement and verification.
The retrofit strategy combined efficient EC technology with airflow-path improvement. Each of the six duties was calculated separately rather than applying one fan selection to every unit. EC operating points were chosen around airflow, pressure, and annual runtime, with speed control, fault feedback, and maintainability included in the design. Larger units received particular attention to array balance and bypass leakage. This avoided the common mistake of installing a fan with an attractive free-air rating but insufficient pressure capability inside the real unit.
Control logic was equally important. EC fans can respond directly to speed commands, but efficiency gains depend on using that capability. Minimum ventilation, temperature or pressure feedback, scheduled setback, soft starting, and fail-safe operation were considered so that the fan would not simply run at maximum speed throughout the day.
The case shows that retrofit value is not limited to electricity. Removing or reducing belts, bearings, and related mechanical service can also lower maintenance effort and unplanned interruption risk. Annual savings should be reviewed against actual tariffs, runtime, and maintenance records.
From a maintenance perspective, AISA PACIFIC SHENGRUI LIMITED considered the removal or reduction of belt-related service, easier access to fan modules, and clearer operating feedback. Trending speed and power can also help identify rising system resistance before it develops into a comfort or process complaint.
A credible retrofit closes the loop with commissioning. Airflow, pressure, power, sound, vibration, and zone conditions should be tested at representative loads. When those results are connected to operating hours and local electricity cost, the owner receives a realistic business case rather than a theoretical efficiency claim.
Frequently Asked Questions
What financial benefit was estimated for the beverage facility?
The source estimate combined about RMB 175,988.4 in annual electricity savings and RMB 22,000 in maintenance savings, totaling roughly RMB 197,988.4.
Where do EC fan energy savings come from?
Savings can come from efficient motors, direct drive, reduced mechanical losses, improved airflow paths, and speed control that follows actual demand.
Does an EC fan retrofit require changes to the control system?
Usually yes. The project should define speed commands, minimum ventilation, sensor feedback, alarm handling, and fail-safe operation with the existing controls or BMS.
How can maintenance requirements change after the retrofit?
Direct-drive EC fans can remove belt adjustment and replacement tasks, while speed and fault feedback can make developing airflow problems easier to identify.
How should long-term savings be verified?
Compare power and operating hours under equivalent loads, and normalize results for airflow, pressure, occupancy, production level, weather, and filter condition where relevant.
