When a long-term client in East Hartford, Connecticut expanded their manufacturing facility, they faced a challenge: their existing 100% air recirculation and filtration system could not keep up with their dust control needs.

Here is how Controlled Air designed and installed a custom solution to eliminate the dust, support their facility expansion, and ensure precise climate control.

The Challenge: When AIR Recirculation Isn’t Enough

For years, the client relied on standard air recirculation with high-efficiency filtration. While this setup works for many applications, the high volume of particulates from their manufacturing processes left lingering dust in the air.

With a major facility expansion underway, the client needed a solution. They required a system that could handle heavy-duty dust collection across multiple stations. To solve the dust problem for good, we needed to move away from recirculation and shift to a single-pass, high-volume air strategy.

The Solution: 100% Outside Air and Precision Engineering

Our engineering and installation teams transitioned the facility to a 100% outside air system. Instead of trapping and filtering the same air repeatedly, the new system draws fresh air from outdoors, filters it, circulates it through the plant, and filters it again and then exhausts the filtered air through the roof.

• Custom Spiral Round Galvanized Ductwork
  • Industrial dust collection requires high velocity to keep particles moving without settling inside the ribs of the system. We reworked the existing ductwork and fabricated new, heavy-duty spiral round galvanized steel ducts. Round ductwork minimizes friction loss and prevents dead zones where dust can accumulate, ensuring optimal airflow.
• 8,000 CFM Direct-Fired Make-Up Air Unit (MAU)
  • Bringing in 100% outside air means you inherit the outdoor weather. To maintain a stable indoor temperature during cold Connecticut winters, we installed an Direct-Fired Heated Make-Up Air Unit. This system automatically triggers and heats incoming air whenever outdoor temperatures drop below a specific set point, preserving worker comfort without driving up energy bills.
• Single-Source Design-Build Execution
  • As a design-build contractor, Controlled Air managed every phase of this complex industrial retrofit:
    • Structural Integrity: We secured an engineer’s stamp for a full structural review and installed weld-free bar joist clamp kits for structural steel bracing.
    • Rigging & Logistics: We coordinated the crane services to lift and place the heavy MAU and roof curbs.
    • Turnkey Controls: Our team handled all power and control wiring, integrating a programmable time clock and disconnect switches for easy operation.
    • Committed Craftsmanship: We connected the new system to existing gas piping, painted the lines safety yellow, and partnered with a certified roofer to guarantee leak-free roof penetrations and flashing.

The Results: Cleaner Air, Better Value

By testing, balancing, and commissioning the total CFM of the new MAU, our technicians ensured the building stays properly pressurized. The benefits for our East Hartford client were immediate:

• Zero Dust Recirculation: The single-pass system exhausts particulates immediately, drastically improving indoor air quality.
• Seamless Integration: The new layout fits perfectly within the expanded manufacturing footprint.
• Energy-Efficient Heating: The direct-fired MAU applies heat only when necessary, keeping operational costs low.

If your industrial manufacturing company is facing air quality issues, reach out to Controlled Air about how we can engineer a better solution for your company.

The post Enhancing Air Quality and Efficiency: A Case Study in Industrial Dust Control appeared first on Controlled Air.

We are proud to announce the successful completion of a massive HVAC integration for the Yanmar Tractor and Parts Warehouses. For this project, Controlled Air served as the lead organizer and turnkey provider, delivering a seamless “design-to-execution” experience that modernized the climate control for two massive industrial spaces.

Here is a look behind the scenes at how Controlled Air managed this complex infrastructure project.

The Scope: Total Project Management

This was not a simple “swap and drop” equipment changeout. This was a comprehensive facility upgrade. 

Beyond the mechanical installation, our team managed the critical logistics to keep the project running smoothly:

• Structural & Architectural: We handled the structural reviews and the installation of pre-engineered deck support systems to safely hold the new heavy-duty equipment.
• Roofing & Rigging: From crane rentals and rigging to the necessary roofing repairs and curb installations, we ensured the building envelope remained secure.
• Utilities & Safety: We managed the complete gas piping infrastructure, electrical connections, and fire alarm tie-ins (including duct smoke detectors).

The Technology: High-Efficiency Synergy

One of the most exciting aspects of this project was the equipment selection. We paired high-performance air handling with Yanmar’s own cutting-edge engine technology.

To condition this massive space, we furnished and installed a robust system designed for longevity and efficiency:

• Air Handling: Seven (7) Aaon 30-ton Rooftop AHUs, fully equipped with VFD blowers for energy efficiency and a high-grade filtration system using MERV 8 and MERV 13 filters.
• Heating & Cooling: These units are powered by fourteen (14) Yanmar 14-ton Gas Heat Pumps (GHP). This 2-pipe natural gas system utilizes Yanmar’s engine technology to provide efficient heating and cooling with reduced electrical demand.
• Reliability: The system includes custom 14″ roof curbs, stainless steel drain pans, and vibration isolation to ensure quiet, long-term operation.

2. The Parts Warehouse

Similar to the tractor facility, the parts warehouse received a top-tier upgrade:

• Three (3) Aaon 30-ton Rooftop AHUs paired with six (6) Yanmar 14-ton GHPs.
• This setup ensures that valuable inventory is kept at consistent temperatures while maintaining high air quality standards through double-wall cabinets and advanced filtration.

Intelligent Controls

Controlled Air furnished and installed a complete Johnson Controls ecosystem to tie the entire facility together.

We deployed panel-mounted controllers across both warehouses, complete with all necessary sensors, relays, and current switches. For the Parts Warehouse, we installed a Johnson Controls Supervisory front-end controller. This web-based user interface allows facility managers to monitor the system remotely, ensuring peak performance and immediate diagnostics.

The Controlled Air Difference

By handling everything from the certified air balancing and start-up testing to the permits and gas meter coordination, Controlled Air ensured that Yanmar could focus on their business while we handled their building.

We are thrilled to hand over a facility that is energy-efficient, structurally sound, and controlled by the latest in building automation technology.

Do you have a complex commercial or industrial HVAC project? Contact Controlled Air today to see how we can organize your next project from start to finish.

The post  Delivering a Turnkey Energy Efficient HVAC Solution for Yanmar Warehouses appeared first on Controlled Air.

BAUSCH Advanced Technology Group has over 60 years in engineering and manufacturing. Bausch has divisions located here in the USA, Germany, Brazil, and Switzerland. They offering table top units for small batches up to high speed fully automatic production lines for Syringes, Cartridges, Vials, Bottles, Ampoules, Bags and various other containers. Cleanrooms are used in industries and manufacturing processes where small particles can adversely affect the outcome. Cleanrooms can vary in size and complexity based on an individual companies’ needs. A cleanroom is a contained space where there is reduced particulate contamination and extensive control other environmental parameters such as temperature, humidity and pressure. One of the main components is the High Efficiency Particulate Air (HEPA) filter that is used to trap particles that are 0.3 micron and larger in size.

The clean room installed at Bausch Advanced Technology was manufactured by PortaFab. The PortaFab cleanroom is a series 300 fire and sound proof modular cleanroom. The Series 300 wall system is often used for creating standalone units like this ISO 7 cleanroom for medical device manufacturing. The load-bearing roof supports HVAC equipment, provides easy maintenance access, and is anti-static which is ideal in manufacturing situations. You can read more them here.

Furthermore, Controlled Air Inc. designed, and installed the complete HVAC system. The installation included an AAON air handling unit with modulating hot gas reheat, digital compressors with 2 lead stages and variable speed compressor fan head pressure control. We also designed and installed a custom duct air distribution system to supply the fan powered HEPA supply terminals along with the air return system. Controlled Air Inc. engineered and installed a Johnson Controls system with a FX-80 Supervisory controller, Web based user interface, room pressure sensors for the cleanroom, AHU control, 8 VAV boxes.

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PCC Structurals Wax Room Chiller – An aging process chiller put the production capabilities of PCC Structurals at risk so they turned to Controlled Air, Inc. to design and build a new process cooling system. Controlled Air, Inc. recommended installing a new chiller on the roof so a steel support system was designed and installed. A new Carrier chiller controlled by a Johnson Control Metasys energy management system provides both process and comfort cooling. PCC Structurals now enjoys a reliable and energy efficient system.

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