The Challenge
Located in the humid Southeast, Coastal Logistics Group operated a sprawling 200,000-square-foot distribution center where summer temperatures inside the warehouse regularly exceeded 95°F (35°C). The company relied on 35 high-speed floor fans scattered across the facility, which created noisy, turbulent air, consumed excessive energy, and still left "dead zones" with no airflow. Employee fatigue was high, turnover was increasing, and product integrity for temperature-sensitive goods was a constant concern.

The Solution
After a thorough site evaluation, we recommended the installation of 12 custom-engineered HVLS (High Volume, Low Speed) ceiling fans, each measuring 24 feet in diameter. The fans were strategically positioned above high-traffic picking zones, packing stations, and break areas.

The Installation
The installation was completed in phases over a single weekend to avoid disrupting operations. Our team utilized the existing steel I-beams with our universal mounting system, requiring no structural modifications to the building.

The Results

• Energy Savings: By destratifying the air—pushing hot trapped air down from the 40-foot ceiling in winter and creating a cooling breeze in summer—the facility reduced its HVAC runtime by 32% and eliminated the need for all 35 floor fans, resulting in an annual energy cost reduction of over $18,000.

• Employee Satisfaction: Worker complaints related to heat stress dropped to zero. The quiet, gentle breeze eliminated the "wind tunnel" effect of floor fans, making communication easier and improving morale.

• Productivity: Packing throughput increased by 15% during peak summer months, as staff were able to maintain consistent pace without heat-related breaks.

• ROI: The entire system paid for itself within 14 months through energy savings and reduced maintenance costs alone."We were worried that large industrial fans would look out of place and create noise. Instead, they've become a talking point—people ask about them every week. And the comfort level during summer services is night and day."    — Warehouse Director