Warehouse Heat
Redistribution
Airflow Simulation & Heat Redistribution
Vent-Tech were engaged by a UK distribution warehouse to investigate airflow issues caused by a newly installed mezzanine floor, which had disrupted heat distribution within the space.
However the design itself proved to be flawed, so Vent-Tech carried out a full 3D scan of the facility and used airflow simulation to identify the most effective solution before any installation took place.
The Problem
The warehouse was suffering from significant temperature imbalance caused by changes to airflow behaviour within the space.
Warm air was rising and becoming trapped at roof level and above the mezzanine, while packing teams working below were exposed to colder conditions. The issue was not the heating capacity itself, but how the air was moving through the building.
This resulted in:
- Heat pooling at the roof level
- Cold zones at operator height
- Ineffective destratification
- Continuous heater runtime
- Staff discomfort in sedentary areas
The client required a solution that would improve heat distribution without defaulting to additional plant or guesswork
The Approach
Vent-Tech adopted a data-led engineering approach to understand airflow behaviour before making any physical changes.
- Conducted a full 3D laser scan of the warehouse
- Created a digital twin of the environment
- Simulated multiple airflow and heater relocation scenarios
- Designed a 3-way plenum heat redistribution system
- Validated performance before implementation
The 3D scan captured key elements including racking layout, mezzanine obstruction, roof geometry, and heater positions, ensuring the model reflected real-world conditions.
Using computational airflow modelling, we analysed heat accumulation at roof level, discharge patterns, recirculation behaviour, and temperature distribution at operator level.
Rather than relying on assumption, multiple configurations were tested digitally, including heater positions, discharge angles, and interaction with the mezzanine.
The Solution
Following simulation validation, Vent-Tech implemented a targeted heat redistribution strategy.
This included:
- Relocation of gas heaters to optimised positions
- Adjustment of discharge orientation
- Installation of a 3-way plenum snorkel heat redistribution system
The snorkel system was designed to reclaim heat at roof level and redistribute it back into occupied zones.
The system includes a high-level intake, ducted extraction fan, and 3-way plenum discharge with double deflection grilles, allowing warm air to be drawn down and redistributed at low level in a controlled manner.
The Result
The outcome was a measurable improvement in temperature consistency across the warehouse.
- Operator-level temperatures increased
- Heat distribution became more uniform
- Stratification was significantly reduced
- Heater efficiency improved
- Staff comfort improved in working areas
Most importantly, the performance of the solution was validated through simulation before installation, removing uncertainty from the process.
The staff in the warehouse were asked for feedback following installation.
One team member initially questioned whether the system would be effective. However, once operational, they commented:
“I get it now, it’s really clever and works well to bring the heat over to where we need it.”
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