Air handling units don’t last forever, but complete replacement isn’t always necessary. Strategic upgrades can extend useful life, improve efficiency, and enhance performance at a fraction of replacement cost.
When to Consider Upgrades
Rising Energy Costs
Older AHUs often use more energy than modern equivalents. If energy bills are climbing despite stable usage, inefficient equipment may be responsible.
Performance Decline
Units that once maintained conditions comfortably now struggle. Temperature control is inconsistent, humidity management is poor, or airflow has reduced.
Maintenance Burden
Frequent breakdowns, hard-to-source parts, and increasing repair costs suggest equipment is approaching end of life. Upgrades can reset the maintenance clock.
Compliance Requirements
Regulations evolve. Equipment meeting standards when installed may no longer comply. Upgrades can address compliance gaps without full replacement.
Building Use Changes
Changed occupancy, different activities, or altered layouts may mean the original AHU specification no longer matches requirements.
Upgrade Options
Fan Upgrades
Replacing old fans with modern EC (electronically commutated) alternatives delivers significant energy savings. EC fans adjust speed to match demand, avoiding the energy waste of constant-speed operation. Payback periods of two to four years are common.
Motor Replacements
Even without changing fans, replacing motors with high-efficiency IE3 or IE4 alternatives reduces energy consumption. Simple upgrade with meaningful savings.
Heat Recovery Addition
Adding heat recovery to units without it captures energy from exhaust air to pre-condition incoming air. Reduces heating and cooling loads substantially. Particularly valuable for high ventilation rate applications.
Control System Upgrades
Modern controls enable demand-based ventilation, optimal start/stop, and integration with building management systems. Better control means better efficiency and comfort.
Coil Replacements
Degraded coils reduce heat transfer efficiency. Replacement restores performance and may enable capacity improvements if original coils were undersized.
Filter Upgrades
Higher-grade filtration improves air quality but increases pressure drop. Upgrading to modern low-pressure-drop filters maintains air quality while reducing fan energy.
VSD Installation
Variable speed drives on existing fans enable speed control, reducing energy consumption at part load. Retrofit VSDs offer good returns where fans currently run at constant speed.
Upgrade vs Replace
The decision depends on several factors:
Age and Condition
Units over 20 years old may have multiple components approaching end of life. Upgrading one element doesn’t address others that will fail soon. Full replacement may prove more economical.
Structural Integrity
If the casing is corroded, insulation is degraded, or the frame is compromised, component upgrades won’t address fundamental problems.
Performance Gap
Minor improvements suit upgrades. If current performance is significantly below requirements, replacement may be the only viable solution.
Future Plans
If building changes are planned, designing new equipment for future requirements may beat upgrading for current needs.
The Upgrade Process
Assessment
We evaluate current equipment condition, performance against requirements, and upgrade opportunities. This assessment identifies the most beneficial interventions.
Design
Upgrade designs ensure new components integrate properly with existing equipment. Compatibility is essential for successful outcomes.
Implementation
Upgrades can often be completed with minimal disruption, sometimes outside operating hours. We plan work to minimise impact on building operations.
Commissioning
Upgraded systems require recommissioning to optimise performance. We verify upgraded equipment delivers expected improvements.
Talk to Us
If your AHU is underperforming or costing too much to run, contact i-Flow to discuss upgrade options.
