The CFD simulation showed that the proposed solution would actually not solve the problem, due to some peculiarities in the plant layout. The supplier's engineers used the simulation to evaluate alternatives and came up with a new approach that used different equipment in different locations to overcome the layout issues. They then used simulation to optimize the equipment capacity, providing the required cooling at the lowest possible cost. The solution worked so well that the plastics manufacturer has already installed it at four similar plants located around the world.
When the company built its first plant, temperatures were far too high for the machines and materials, not to mention the people working in the plant. The company called in a representative from Applied Air, Dallas, to discuss adding cooling equipment to the plant. A limiting factor was that the air space above the machines is utilized by cranes and other equipment, making it impossible to install overhead fans. Also, plant personnel work along the walls that run parallel to the rows of machines, limiting the placement of equipment in that area.