Evaporative cooling systems

INTRODUCTION

Flexible Engineering designs, supplies and installs complete evaporative cooling systems for industrial, commercial, agricultural and large-volume applications. We provide both positive-pressure (direct discharge) evaporative air coolers and engineered negative-pressure pad-and-fan cooling systems. Our solutions are designed to deliver high airflow capacity, superior cooling efficiency, low operating cost and long service life in demanding environments.

This document provides a comprehensive technical overview of our evaporative cooling product range, including high-capacity airflow models such as 18,000 m³/h, 25,000 m³/h and 30,000 m³/h units, as well as full-building negative pressure cooling systems with cooling pads and exhaust fans.

PRINCIPLE OF EVAPORATIVE COOLING

Evaporative cooling operates on a natural thermodynamic principle. When warm air passes through water-saturated cooling media (pads), a portion of the water evaporates. This evaporation absorbs heat from the air, reducing its dry-bulb temperature while slightly increasing humidity.

Unlike conventional refrigeration systems, evaporative cooling:

• Uses no refrigerants
• Consumes significantly less electrical energy
• Continuously introduces fresh air
• Provides natural ventilation and air exchange
• Reduces carbon footprint and operating costs

This makes evaporative cooling ideal for factories, warehouses, poultry farms, greenhouses, workshops and other large air-volume spaces.

POSITIVE PRESSURE EVAPORATIVE AIR COOLERS

Positive pressure evaporative coolers use powerful fans to push cooled air directly into the building. These units can be roof-mounted, wall-mounted or ducted, and are ideal for spot cooling or full-space cooling.

MODEL RANGE – HIGH AIRFLOW INDUSTRIAL UNITS

Model FE-18000

• Airflow: 18,000 m³/h
• Power Supply: 380V / 50Hz (3 Phase)
• Fan Type: Axial
• Motor Power: 1.1 kW
• Cooling Pad Thickness: 100 mm
• Water Tank Capacity: 30–40 Litres
• Effective Coverage Area: 150–200 m²
• Air Discharge: Top / Side discharge options
• Noise Level: ≤ 75 dB
• Water Consumption: 10–15 L/hr (approx.)

Model FE-25000

• Airflow: 25,000 m³/h
• Power Supply: 380V / 50Hz (3 Phase)
• Motor Power: 1.5 kW
• Pad Thickness: 100–150 mm high-efficiency cellulose media
• Effective Coverage Area: 200–300 m²
• Static Pressure Capability: Medium to high
• Water Tank: 40–50 Litres
• Heavy-duty industrial housing

Model FE-30000

• Airflow: 30,000 m³/h
• Motor Power: 2.2 kW
• Fan Diameter: Large axial fan for high throw distance
• Cooling Pad Area: Extended surface for maximum evaporation
• Coverage Area: 300–400 m²
• Industrial-grade corrosion-resistant casing
• Variable speed drive compatible
• Suitable for ducted or direct discharge systems

All units are manufactured using corrosion-resistant materials such as powder-coated steel, stainless steel or reinforced polymer housings. Cooling media are high-efficiency cross-fluted cellulose pads designed for maximum surface area and long service life.

NEGATIVE PRESSURE PAD-AND-FAN COOLING SYSTEM

Flexible Engineering provides complete negative pressure evaporative cooling systems for large industrial and agricultural structures.

In this system:

• Cooling pads are installed on one side (air inlet side) of the building.
• High-capacity exhaust fans are installed on the opposite end.
• When fans operate, they create negative pressure inside the building.
• Fresh air is drawn through the wetted cooling pads.
• The air cools as it passes through the pads and flows across the building.
• Warm air is expelled through exhaust fans.

This creates continuous air movement, full air exchange and uniform temperature distribution.

Cooling Pad Specifications

• Material: High-density cellulose evaporative media
• Thickness Options: 100 mm / 150 mm / 200 mm
• Height: Custom fabricated to building requirement
• Frame: Aluminium or GI structure
• Water Distribution: PVC header pipe with uniform spray nozzles
• Water Recirculation: Sump tank with pump system
• Anti-algae treatment available

Exhaust Fan Specifications

Industrial Exhaust Fan Models:

• 36 inch fan – Airflow approx. 28,000–30,000 m³/h
• 42 inch fan – Airflow approx. 35,000–40,000 m³/h
• 50 inch fan – Airflow approx. 44,000–50,000 m³/h

Specifications:

• Frame: Galvanized sheet / Stainless steel
• Blades: Aluminium alloy or stainless steel
• Motor: IP55 rated
• Power: 0.75 kW – 1.5 kW depending on size
• Belt-driven or direct-drive options
• Automatic shutter system

COMPLETE SYSTEM DESIGN APPROACH

Flexible Engineering provides turnkey solutions including:

• Heat load calculation
• Air change rate determination
• Fan quantity and placement design
• Pad area calculation
• Structural support design
• Water piping layout
• Electrical panel with control system
• Installation and commissioning
• Preventive maintenance services

System design is customized based on:

• Building dimensions
• Internal heat load
• Local climate conditions
• Required temperature reduction
• Air change per hour requirement

ADVANTAGES OF OUR SYSTEMS

• Up to 70–80% lower energy consumption compared to conventional air conditioning
• Fresh air ventilation
• Lower capital cost for large spaces
• Environmentally friendly (no refrigerants)
• Easy installation and scalability
• Reduced operating expenses
• Suitable for industrial, commercial and agricultural use

APPLICATIONS

• Factories and manufacturing plants
• Warehouses and logistics centres
• Poultry and livestock farms
• Greenhouses
• Workshops and fabrication units
• Automotive garages
• Event halls and semi-open commercial spaces

WHY CHOOSE FLEXIBLE ENGINEERING

Flexible Engineering delivers complete cooling solutions under one roof — from engineering design to supply, installation and maintenance. Our systems are built for durability, high airflow efficiency and long operational life in tropical and industrial environments.

We do not simply supply equipment — we provide engineered cooling solutions tailored to your facility requirements.