When it comes to environmental control requirements, no two industries, companies, or applications are the same. Our customers often struggle to find environmental control units (ECUs) robust and sophisticated enough to maintain precise temperatures, humidity, pressure, and cleanliness in a way that meets their unique requirements. That’s why we’re here.

From homeland security and semiconductors to military and aerospace, Air Innovations designs and manufactures world-class custom ECUs tailored to your industry’s standards and to the specific needs of your application.

Some customers have specialized equipment or components requiring pristine environmental conditions or certain processes requiring a controlled environment. We build one-off custom solutions for complex applications, custom systems designed for repeat builds, or projects that will be part of larger environmental control systems.

Here are examples of areas in which we’ve helped our customers overcome challenges with custom ECU solutions:

  • Pharmaceutical research and manufacturing
  • Research and development laboratories
  • Hospital laboratories
  • Material handling
  • Injection molding
  • Process manufacturing
  • Advanced engineering projects (observation wheels)

We also have deep experience with Class 1 Div. 1 and Class 1 Div. II explosion-proof environmental control units.

To account for a wide range of different applications, our custom ECUs are available in three configurations:

  • Integrated– These units accommodate existing equipment structures, resulting in a smaller footprint, greater system efficiency, and lower installation costs.
  • Mounted– These units are attached to an existing system and can reduce a system’s overall weight and footprint.
  • Standalone– These units are placed around equipment rather than in or on them, allowing for greater flexibility regarding system location, installation, configuration, and performance capabilities.

DESIGNING A CUSTOM ENVIRONMENTAL CONTROL UNIT (ECU)

A. Identify Environmental Control Needs
B. Select Your ECU Configuration
C. Customize Features
D. Consult on Project Design & Quote

Our systems address four environmental control needs:

1. Temperature control: Control environments from 0°F to 100°F ( -18°C to 38°C) with tolerances as precise as ±0.02°C.

  • Indoor desired conditions typically run somewhere between 38°F and 85°F (3°C and 29°C).
  • Temperature control for “outdoor” (or ambient) conditions vs. the “indoor” (or desired) conditions the client wants. We have designed systems to operate in conditions as extreme as -20°F to 125°F (-29°C to 52°C).
A. Identify Environmental Control Needs
Humidity and dew point control

Our systems address four environmental control needs:

2. Humidity and dew point control:

  • Relative humidity: Control tolerances to ±0.5% RH; up to 95% RH
  • Dew point: Control tolerances to as dry as -60°C to near saturation
HEPA Filter

Our systems address four environmental control needs:

3. Filtration:

  • HEPA
  • ULPA
  • Molecular

4. Pressurization:

  • Negative Pressure
  • Positive Pressure
Change Per Hour Graphic

Combinations of Environmental Factors:

  • Most systems we work with require some combination of these factors and generally in either a range (temperature or humidity range) and even the amount of change permitted to these ranges over time.
  • For example, a customer could allow a temperature range of 70-75°F (21-24°C) for the overall system, with no more than a 1-degree change per hour.
Readout

Execution:

  • How precisely do you need these environmental conditions controlled?
  • What is the desired level of cleanliness and in what amount of time?
Mounted OEM Rendering
Example of a mounted system

Our ECUs are available in three configurations:

  1. Integrated: These units are designed to operate inside another piece of equipment structure, resulting in a smaller footprint, greater system efficiency, and lower installation costs.
  2. Mounted: These units are attached to an existing system and can be designed to reduce a system’s overall weight and footprint.
  3. Standalone: These units are placed around equipment rather than in or on them, allowing for greater flexibility regarding system location, installation, configuration, and performance capabilities.
Customize Features

The characteristics of our environmental control units regularly include the following:

Our experts provide custom HVAC system design, prototype building, testing, and manufacturing services. By offering complete custom solutions, we ensure the system we deliver fully complies with the requirements and restrictions of the application.

Consult on Project Design & Quote

Once our team completes the custom ECU design, we will provide you with all of the necessary specs and mockups for review to ensure the design meets all of your requirements. After any final revisions, the team will then proceed with generating a project quote.

To learn more about Air Innovations’ custom design capabilities and services for your ECU, contact us today.

CORE CAPABILITIES IN CUSTOM ENVIRONMENTAL CONTROL

Our environmental control systems can be customized to meet your broad to precise temperature control, humidity, and filtration needs. We have experience working on a variety of projects with these tolerances:

  • Precise or Broad Range Temperature Control:

Control environments from 0°F to 100°F (-18°C and 38°C) with tolerances as precise as ±0.02°C.

Indoor desired conditions typically run somewhere between 38°F and 85°F (3°C and 29°C). Temperature control for “outdoor” or ambient conditions vs. the “indoor” (or desired) conditions the client wants. We have designed systems to operate in conditions as extreme as -20°F and 125°F (-29°C to 52°C).

  • Humidity and Dew Point Control:

Humidification and dehumidification, ultrasonic or steam humidification. Control relative humidity tolerances to ±0.5% RH; up to 95% RH. Control dew point tolerances to -60°C to near saturation.

  • Filtration:

HEPA, ULPA, or molecular filtration.

  • Pressurization:

Negative pressure or positive pressure.

Additionally, our systems can be customized with the following features:

  • Customized sizing or configuration
  • Explosion-proof capabilities
  • Mil-Spec or Semi Standards
  • Stationary or mobile units
  • DX, chilled water, or thermoelectric cooling
  • Up to 5,000 CFM
  • 3,000 to 180,000 BTU/h cooling capacity
  • UV sterilization

Other Considerations When Designing Custom Solutions

There are several considerations that our engineering team needs to account for when designing an environmental control unit for your specific application. We not only have to guarantee the protection of your sensitive processes within your given parameters but also to ensure the system can function properly in the environment in which it will reside. Here are a few things we typically consider:

  • Cost
  • Ambient temperature and humidity conditions
  • Volumetric airflow: How much air they need to pass through the system in a period of time, typically in cubic feet per minute (CFM).
  • Once-through air or recirculation of air: Air can be much cleaner if it’s recirculated through a captive space.
  • Redundancy: How critical is it for the system never to go down?
  • Environmental exposure: Will the system be exposed to environmental conditions like chemicals, weather, transportation, military settings, explosion-proofing, and/or seismicity?
  • Variation of the heat load: A system might need to go down to -2° C (29°F) in January but hit 106°F or higher in July. The system has to be designed to deal with those extremes.
  • Environmental friendliness/certifications: The global warming/environmental impact potential of the refrigerant used within the system.
  • Electrical characteristics: 50Hz/60Hz or other; systems on a ship or plane may have different characteristics.
  • Construction materials: Material factors for system construction usually depend on the factors above.

Benefits of Air Innovations Custom Solutions

Our multi-disciplined engineers provide innovative concept designs, prototype building, testing, and manufacturing services. We maintain an in-house research and development department specializing in conducting data and performance validations. Our psychrometric testing chamber enables our team to simulate environmental controls to ensure the performance of our custom units.

Air Innovations experts work on everything from expansive solutions to small/constrained-space environmental control systems. We also offer 24/7 service and product warranty support. By offering complete custom solutions, we ensure the systems we deliver fully comply with industry and application requirements.

Clients around the world have trusted Air Innovations. Contact us today to learn more about our custom ECUs or discuss your application requirements with one of our experts

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