Established in 1982, Nuneaton Signs Ltd is an award winning UK sign manufacturer and a social enterprise, providing employment and training opportunities for people with disabilities. Committed to sustainability and efficiency, the company manufacture road, commercial and bespoke signage for a wide range of clients.
As part of its Net Zero commitment, Nuneaton Signs commissioned an independent energy audit to identify opportunities for reducing energy waste and improving efficiency. This revealed a significant temperature imbalance between the floor and ceiling across its 1,500m² facility, which featured a sloped ceiling, measuring 5.75m at the walls, rising to 6.75m at the apex.
The ceiling accumulated a significant amount of heat from the HVAC system despite not being particularly high, leading to severe thermal stratification. This forced upstairs office areas to use air conditioning even during winter, in efforts to maintain comfort on the shop floor. This was a clear indication of energy wastage, increasing energy consumption and costs.
Following a free site survey and energy/carbon reduction estimate, Airius installed 14 Model 25 Standard Series destratification fans across the two workshop areas, both fitted with independent speed controllers.
Installed over the walkways at 6 metres and the apex, the Airius fans continuously recirculate high-level warm air to the floor in colder months to balance temperatures throughout the facility, reducing heat loss, maximising heating efficiency and lowering energy costs.
This significantly reduced heating output and improved comfort, while reducing air conditioning demand in upstairs offices. In warmer months, the improved airflow circulation enhances cooling, reducing the need for energy-intensive air conditioning.
With 50% funding secured through the Warwickshire Business Energy Advice Services (WBEAS) Business Support Programme, the project was even more cost-effective. Installation took place outside normal working hours, ensuring no disruption to production.
Delivering immediate energy reductions, the Airius system cut gas consumption by 23% in the first month, saving nearly £600, while also improving employee comfort at all levels of the facility and significantly reducing carbon emissions.
“Airius destratification fans were installed after some consultation works with the Carbon Trust. The installation of these fans is simple. The effectiveness is felt immediately. We were able to reduce the running times of our warm air heating system dramatically yet still retain a comfortable environment for staff and customers. A worthwhile investment!” Ian Whitelaw – Director Read in full
"The temperature in the church with the fans running is more even and feels warmer now that we “harvest” all that heat in the roof and the fans are very economical to run. We have kept the congregation from freezing and managed to reduce the boiler burning time by about 25%. We think the Airius product speaks for itself.” Peter Hill – Director of Facilities Read in full
