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The Netherlands: a can manufacturer
A pioneering climate control solution helped Canpack create the perfect production environment; reducing heat stress, cutting energy consumption, and improving wellbeing.
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THE FRESH FACTORY EXPERIENCE
See how the Fresh Factory concept created a healthier, more efficient manufacturing environment for a global can manufacturer.
What is a Fresh Factory ?
A Fresh Factory is a production environment designed to optimise comfort, temperature control and air quality. Through intelligent ventilation and climate control strategies, it creates healthier, more productive workplaces, even in demanding industrial environments. The result is improved employee wellbeing, enhanced operational performance and reduced energy consumption.
A Can Manufacturer’s Challenge
Tackling Heat in a Demanding Environment
The manufacturing processes at Canpack's facility in Helmond, Netherlands, generate significant heat, creating challenging working conditions. The objective was to improve employee comfort through effective ventilation and cooling while maintaining a simple, energy-efficient system.
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A pioneering climate control solution helped Canpack create the perfect production environment – reducing heat stress, cutting energy consumption, and improving wellbeing.
Proven Results for People and Performance
Performance Guaranteed
Kingspan Light + Air designed, installed and performance-guaranteed the Fresh Factory solution, ensuring target temperature conditions are consistently achieved. Following its success, the solution is now being considered for implementation across Concept facilities worldwide.
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Our Fresh Factory solution
A Bespoke Natural Ventilation Solution
A detailed analysis of the facility and its production processes formed the basis of a bespoke natural ventilation strategy. By combining ventilation expertise with intelligent control systems, the solution delivers effective heat management while minimising energy consumption.
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See the Fresh Factory concept in action
Learn how the Fresh Factory approach helped Canpack overcome extreme heat challenges and create a healthier, more productive manufacturing environment.
See Fresh Factory in Action Worldwide
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Saudi Arabia: smelter
The Ma'aden site comprises a plot of land 90km north of Jubail on the coast of the Arabian gulf, in Ras Az Zawr The smelter on site is producing 740,000 mtpy of aluminium.
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Italy: food industry
Azienda Agricola Nicolini Marco is a mid-sized agricultural company based in Liguria, Italy, operating mainly in the cultivation of vegetables.
Fresh Factory FAQs
What steps are involved in analysing requirements for an appropriately designed Fresh Factory ?
A thorough work climate survey is essential to assess both indoor and outdoor environmental conditions. This involves a range of measurements, including airflows, thermal loads, humidity levels, contamination, air leakage, and overall air quality. It is also important to consider human factors such as staff metabolism and workwear.
In more complex scenarios, Computational Fluid Dynamics (CFD) technology can be used to simulate and visualise airflow and temperature distribution, providing precise insights before finalising the equipment design.
Is a Fresh Factory suitable for my industry ?
Yes. While particularly effective in heat-intensive environments such as food and beverage production, metalworking, or packaging facilities, the Fresh Factory concept is highly adaptable. It can be tailored to meet the specific needs, processes, and regulatory requirements of a wide range of industrial sectors.
What products are used in a Fresh Factory solution ?
Kingspan Light + Air’s Fresh Factory solutions typically feature adiabatic cooling systems combined with natural ventilation components. These may include natural ventilators (such as the Firelight Duo, Typhoon extract ventilator, and diffusion box), air intake louvres, and an intelligent control system equipped with temperature and wind sensors. Each solution is customised to meet the specific requirements of the building and its operations.
What are the benefits of adopting a Fresh Factory approach ?
In addition to ensuring compliance with fire and smoke safety regulations, a Fresh Factory approach offers several key benefits:
- Enhanced employee wellbeing, leading to reduced absenteeism and lower staff turnover
- Lower energy consumption, for example through the use of adiabatic cooling solutions
- More stable indoor temperatures, helping to maintain consistent product quality
What is Fresh Factory ?
A Fresh Factory goes beyond simply installing a heating or cooling system. It is a production facility designed with an integrated approach to thermal comfort, air quality, and energy efficiency — all aimed at creating a healthier, more productive, and sustainable working environment.
How is climate comfort measured and guaranteed in a Fresh Factory ?
As part of the Fresh Factory approach, Kingspan Light + Air conducts a comprehensive climate survey to assess both internal and external heat loads, along with the necessary extraction and ventilation capacities.
The system is designed to ensure thermal comfort at pre-agreed workstations, even under extreme external conditions — for example, 45°C with 25 g/kg absolute humidity. In these conditions, the system maintains:
- A Predicted Mean Vote (PMV) between -1.5 and +1.5, and
- A Predicted Percentage of Dissatisfied (PPD) of no more than 50%
These values are based on international thermal comfort standards and are validated using precise on-site measurements at operator level.