Food-production ventilation systems require more than standard air-handling equipment. When ultraviolet disinfection is introduced, engineers must consider airflow, temperature, humidity, installation orientation, lamp safety, electrical supply and maintenance access.
This project involved two custom-configured UV sections for the ventilation system of a cheese-production facility.
Project Background
An engineering contractor from Saransk contacted UVL while designing and installing ventilation systems for a cheese plant.
The contractor needed complete bactericidal sections that could be integrated into the supply-air system. Because the equipment would operate at a food-production site, reliability and operational safety were as important as the calculated UV performance.
Initial Operating Parameters
The customer provided the following data:
airflow through each section: 12,450 m³/h;
initially requested volumetric UV dose: 385 J/m³;
final selected dose: 256 J/m³;
target reduction: 99% for Staphylococcus aureus;
relative humidity: 80–90%;
air velocity: 8–9 m/s;
operating temperature: 8–18°C;
required quantity: two UV sections.
The project changed several times as the ventilation design and operating requirements were refined.
High Humidity as an Engineering Constraint
One of the main concerns was the expected humidity downstream of the planned steam humidifier.
The customer wanted to know whether the UV lamps could operate under these conditions and whether prolonged exposure to humid air could accelerate oxidation of the electrical contacts.
High relative humidity does not automatically prevent the use of UV equipment. However, the design must avoid condensation on lamps, connectors, wiring and metal surfaces.
The risks depend on several factors:
the actual air temperature;
the location of the dew point;
whether water droplets or steam can reach the section;
the protection of electrical connections;
the enclosure and cable-entry design;
airflow during startup and shutdown;
access for inspection and preventive maintenance.
Where condensation is possible, simply selecting more powerful lamps does not solve the problem. The contact assemblies, wiring and control equipment must be protected appropriately, and the section must be positioned so that it is not exposed to direct moisture carryover.
During the project, the ventilation design changed and the steam humidifiers were ultimately removed. This made it possible to use the standard section configuration while retaining engineering recommendations for protecting the contact assemblies and monitoring the actual operating conditions.
Antishatter Lamps for Food Production
The second major issue was the customer’s requirement for antishatter lamps.
At food-processing facilities, a damaged glass lamp may create a contamination risk. Antishatter protection can help retain fragments if a lamp is accidentally broken, but the protective layer also affects the transmission of germicidal UV radiation.
This means that switching from a standard lamp to an antishatter version is not a simple component substitution. The complete section may need to be recalculated because the change can affect:
the useful UV output;
the number of lamps;
the required electrical power;
the dimensions of the section;
manufacturing time;
the final price.
Several configurations were therefore evaluated. The customer compared standard and antishatter versions, different target doses and alternative lamp quantities.
After the operating conditions were clarified, the final order was placed for standard sections. Lamp-breakage procedures and safe maintenance nevertheless remained important because the equipment was intended for a food-production facility.
Selecting the Final UV Dose
The original design discussions included a dose of 385 J/m³. This configuration provided a higher reserve but also increased the number of required components and the total project cost.
After reviewing the type of premises and the required microbiological performance, the project was recalculated for 256 J/m³ with a target efficiency of 99% against Staphylococcus aureus.
The revised configuration provided a more appropriate balance between:
microbiological performance;
installed UV capacity;
section dimensions;
power consumption;
production time;
project budget.
Reducing the design value was not treated as a simple price-cutting measure. It was based on the updated requirements for the actual ventilation system and the selected target microorganism.
UV performance in operation still depends on air velocity, lamp output, temperature, contamination of lamp surfaces and maintenance intervals. These parameters must be controlled during commissioning and subsequent operation.
Selected Equipment
The final solution consisted of two UVL-VENT 12 bactericidal sections.
Each section was designed for an airflow of 12,450 m³/h and equipped with 12 UV lamps.
Final Configuration
Equipment: UVL-VENT 12
Quantity: 2 sections
Airflow per section: 12,450 m³/h
Number of lamps: 12 per section
Selected dose: 256 J/m³
Target efficiency: 99% against S. aureus
Installation orientation: vertical
Electrical supply: three-phase
Operating temperature: 8–18°C
Initial relative-humidity data: 80–90%
Delivery set: sections, control cabinets, UV lamps and electronic ballasts
The vertical installation arrangement was agreed during the later stages of the project. The control-cabinet power supply was also changed from a single-phase to a three-phase configuration.
These changes were coordinated before production so that the equipment could be connected to the facility’s electrical and ventilation systems without modifications after delivery.
Why Vertical Installation Mattered
The mounting position affects more than the external layout of a UV section.
A vertical installation requires engineers to consider:
the orientation and secure fixing of the lamps;
access for lamp replacement;
support for the section and adjacent ductwork;
cable routing;
service-door clearance;
the location of the control cabinet;
safe isolation before maintenance.
The installation arrangement must also allow individual lamps to be removed without dismantling a large part of the ventilation system.
For this project, the vertical configuration was confirmed before manufacture and reflected in the final equipment design.
Production and Delivery
Once the technical parameters, pricing and contract terms had been approved, the customer confirmed an order for two UVL-VENT 12 sections.
The manufacturing period was set at 30 working days from receipt of payment. The standard configuration made it possible to maintain this schedule, whereas certain custom moisture-resistant or antishatter versions would have required additional manufacturing time.
Timing was particularly important because the customer had already received project financing and wanted to place the order before the expected price revision.
After production and final preparation, the order was packed as five separate cargo units:
two UV sections;
control cabinets;
UV lamps packed separately for transportation.
The customer arranged collection, supplied the driver’s information and issued the required authorization documents. Closing documents were subsequently exchanged electronically.
The project therefore progressed from initial selection and several recalculations to production and physical shipment of the completed equipment.
Commissioning and Maintenance
Before the system enters regular operation, the installer should verify:
The actual airflow through each section.
The direction and uniformity of the air stream.
Correct three-phase cabinet connection.
Operation of all lamps and electronic ballasts.
Safety interlocks on service doors.
Absence of condensation inside the section.
Clearance for inspection and lamp replacement.
Correct operation of indication and runtime monitoring.
Availability of lamp-breakage and disposal procedures.
The UV sections should operate only when the ventilation system is running. Personnel must not be exposed to direct UVC radiation during inspection or maintenance.
Where high humidity remains possible, the equipment should be inspected regularly for moisture, oxidation and contamination of electrical connections.
Project Benefits
The final configuration provided the contractor with:
a complete UV solution for a cheese-production facility;
two sections sized for 12,450 m³/h each;
a configuration based on the revised microbiological requirement;
lower project cost compared with the initial higher-dose option;
vertical mounting adapted to the ventilation layout;
three-phase control cabinets;
coordinated delivery of sections, lamps, electronic ballasts and controls;
a production schedule compatible with the construction project.
The contractor did not receive a collection of unrelated components. The delivered package was prepared as a complete ventilation-system solution with the mechanical, electrical and operational requirements coordinated in advance.
Conclusion
This project demonstrates why industrial UV air disinfection cannot be selected from airflow alone.
The final equipment configuration was influenced by humidity, temperature, air velocity, target microorganism, antishatter requirements, installation orientation, electrical supply, production time and budget.
After several engineering revisions, the customer received two UVL-VENT 12 sections adapted to the actual ventilation design of the cheese-production facility.
This iterative process was essential: the purpose was not simply to install the maximum possible number of lamps, but to provide a technically justified configuration that could be manufactured, installed and maintained under real operating conditions.
Top comments (0)