Warehouse Air Conditioners: How to Cool a Warehouse

Warehouses are a vital part of the supply chain and manufacturing process, storing every type of commercial goods and inventory parts. However, keeping them cool can be challenging, especially for warehouses located in warm and temperate regions. Proper warehouse cooling is essential to ensure worker safety, protect stored goods, and maintain operational efficiency. 

In this guide, we explore various warehouse cooling solutions, and where they are ideal to use.

The Importance of Warehouse Air Conditioning

When it comes to warehouses, the effects of heat and humidity on both stored goods and workers are actually more detrimental than cold. More than half (55%) of warehouse and storage buildings in the US are non-refrigerated warehouses, necessitating some type of cooling solution.

✔ Worker Safety and Productivity

High temperatures can lead to heat stress, fatigue, and decreased productivity. OSHA recommends 68-76° F and 20%-60% humidity for warehouses.

✔ Preservation of Goods

Certain products, such as perishable foods, electronics, or chemicals, can degrade under excessive heat.

The massive warehouse explosion in Tianjin, China that killed 173 people in 2015 occurred when a container of nitrocellulose degraded in hot weather. Similarly, the Great Molasses Disaster of Boston in 1921 was caused by high temperatures, leading a large storage tank to burst and sending a deadly flood of molasses into city streets.

✔ Equipment Longevity

High temperatures can strain machinery, reducing efficiency and increasing maintenance costs.

✔ Regulatory Compliance

Industries handling temperature-sensitive goods often have strict cooling requirements to meet safety and quality standards.

The Challenges in Cooling Warehouses

Large Design

Warehouses have high ceilings and vast open areas, making them difficult to cool uniformly.

Poor Insulation

Older warehouses can lack proper insulation, causing heat to enter easily.

Equipment Heat

Machinery, lighting, and other equipment can generate significant heat, which are then trapped inside the space.

Frequent Openings

Doors opening frequently for loading and unloading allow hot air to enter.

Humidity Control

Warm spots in the warehouse can cause excess humidity, which can damage goods and equipment in the long term.

Types of Warehouse Air Conditioners

Based on data from the US Energy Information Administration, packaged air conditioners are the most common type of cooling system used by warehouse and storage buildings. Residential-type central air conditioners were the second-most-used cooling equipment.

Here are the different types of warehouse air conditioners and cooling systems.

1. Commercial AC units

Overall, the most commonly used option for cooling warehouses are commercial air conditioners. These units are specially designed to cool large spaces efficiently.

Plus, commercial ac units are safe to operate even in locations that deal with chemicals or other flammable materials.

While we carry many different options for warehouse cooling, you might consider checking out the Friedrich Hazardgard Series Air Conditioner, which is specifically designed for spaces with toxic or flammable liquids and gases.

2. Industrial ceiling fans

If you aren’t sold on your warehouse needing an air conditioning unit, you might opt to install an industrial ceiling fan instead. As hot air in the warehouse rises, an industrial ceiling fan can help redistribute and recirculate the air to make the space more comfortable.

While many people use these fans for cooling, they can also help even out the air when heating your warehouse as well, which can help you save on heating and cooling costs.

3. Spot cooling units

These are portable units that provide targeted cooling to specific areas or workstations.

They are cheap, flexible and mobile, and are ideal for localized cooling.

However, their small size and limited BTU means they are only for spot cooling instead of large-scale cooling.

Our recommended portable AC:

Kwikool KPAC1411-2 KPAC II Series 13,700 BTU Portable Spot Cooler

The KPAC II Series, KwiKool’s Single Duct Line of portable ACs, offers spot cooling for high ambient environments, in a compact solution of just two square feet.

The KPAC1411-2 features 13,700 BTUs and is 16.325″w x 26″d x 37.25″h. It is compact enough to fit in a small space but powerful enough to cool effectively within 5 to 7 feet of the unit. The KPAC II units should be able to achieve a 20°F temperature differential across its coil, keeping your employees a bit more comfortable while working. It will easily fit in a closet to store when not in use.

It comes with a 3-gallon condensate collection tank complete with overflow protection. When the tank is full, the float activation will shut the machine off automatically. Additionally, it includes an automatic restart feature in the event of a power failure.

4. Automated Ventilation Systems

These are centralized systems that use smart technology to optimize cooling for the entire warehouse. This is done through sensors and controls to manage airflow, according to temperature and occupancy levels.

Such systems are energy-efficient, but require high initial investment and higher level of maintenance thanks to the many sensors and units that make up the system.

5. Air Curtains

Air doors or air curtains can help with warehouse cooling by keeping the hot air outside. This can make a crucial difference for warehouses with high-traffic doors and loading areas.  

Based on one study, air curtains can be retrofitted to an already installed door system in case of a change of use (e.g. frequent opening or long stay-open times), whereas replacing a slow running warehouse door with a high-speed one requires a higher investment.

Our recommended warehouse air curtain:

Mars Air Systems High Velocity (HV2) Unheated Air Curtain

The High Velocity 2 Series (HV2) of Mars Air Doors features 1 horsepower motors for efficient wind loads up to 14 ft. high and offers a variety of lengths to provide an environmental barrier at that height. It can also protect your warehouse interior from insects up to 12 feet.

It includes two 1-HP motors and features durable metal construction with a corrosion resistant powder coated Titanium Silver finish. A variety of lengths from 36″ to 144″ is available.

Door limit switches automatically activate and de-activate (start and stop) the air curtain when the door(s) open and close. A controller that offers time delayed control reduces the cycling of the air curtain motors in high traffic areas (10+ times/hour). This type of controller will delay the unit from turning off when the door closes. They can usually be set from 6 seconds to up to 20 minutes.

What to Consider When Choosing a Warehouse Heater

🗹 Warehouse Size and Layout

Larger warehouses may need a combination of cooling methods and not just one air conditioning system.

🗹 Climate

Local weather conditions influence the choice of cooling systems. Industrial fans may be enough for warehouses in colder regions, but high BTU air conditioners may be necessary for warehouses in warmer climates.

🗹 Budget

Consider upfront costs, operating expenses, and maintenance requirements. Automated ventilation systems are more expensive than individual commercial AC units, but may be more efficient in the long run.

🗹 Type of Goods Stored

Temperature-sensitive products demand more robust cooling solutions, along with humidity control.

🗹 Energy Efficiency

Look for systems with high energy efficiency ratings to minimize costs. EnergyStar-certified AC units are more efficient compared to non-certified ones.

🗹 Flexibility

For warehouses with changing layouts, modular or portable solutions could be more ideal.

🗹 Safety Regulations

Make sure local safety codes and ventilation requirements are met. The AC unit/s or cooling system should have enough BTUs to cool the warehouse space and meet the minimum storage temperature for the goods stored.

Conclusion

Effective warehouse cooling is vital for maintaining operational efficiency, ensuring worker safety, and protecting stored goods. Investing in energy-efficient and well-maintained cooling systems not only reduces operational costs but also enhances overall productivity. Check out our energy-efficient warehouse air conditioners to keep your warehouse chill and productive through the hot summer months!