Air Washer Unit

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Air Washer Unit

1. Overview

Air Washer Unit or Air Cooling Unit, is an air handling system designed to
supply filtered and conditioned (cooled or fresh) air to indoor spaces.

  • Primary functions:
    • Provide fresh air for ventilation.
    • Reduce heat and control odors / fumes.
    • Maintain positive air pressure to prevent ingress of dust and
      pollutants.
    • Improve occupant comfort by lowering air temperature and
      increasing air quality.

These units are widely used in:

  • Commercial kitchens: To supply fresh, filtered air and balance exhaust
    losses from kitchen hoods.
  • Industrial & factory spaces: For cooling and ventilation in manufacturing environments.
    losses from kitchen hoods.
  • Warehouses: To improve ventilation, maintain temperature, and control
    dust.
  • Commercial applications: Shopping malls, event halls, large canteens,
    etc.

2. Construction Features:

A standard Air Washer / Fresh Air Unit is made up of the following components:

Component Description
Casing / Enclosure Made from galvanized steel, aluminum, or stainless steel with thermal/acoustic insulation to reduce noise and prevent heat gain/loss.
Filter Section Pre-filters or fine filters to remove dust, smoke particles, and other contaminants from incoming air.
Cooling Section Can be Evaporative Cooling Pads / Air Washer / Spray
nozzles for mechanical cooling. In air washers, the cooling happens through water spraying over cellulose pads.
Spray Pump & Water
Distribution System
Pumps water from the tank to spray nozzles or distribute over cooling pads for evaporative cooling.
Tank / Sump Stores recirculated water used for cooling.
Blower / Fan Section Centrifugal or axial fans sized to provide required airflow, driven by electric motor (direct or belt drive).
Drain & Overflow
Provisions
To remove excess water and prevent stagnation

3. Working Principle:

  • Fresh air is drawn from outside through the filters.
  • Air passes through the cooling section:
    • In Air Washer (Evaporative Cooling): Water is sprayed over pads
      or media; air passes through them, absorbing moisture and
      reducing temperature by 5–12°C (depending on climate and
      humidity).
    • The blower delivers the conditioned air into the duct system for
      distribution.
  • In kitchens, the unit balances exhaust air losses, preventing negative
    pressure.
  • In factories/warehouses, it provides cooling and dilutes contaminants.

4. Applications:

Commercial Kitchens

  • Balances air removed by kitchen exhaust systems.
  • Supplies filtered, cool air for chefs and staff comfort.
  • Helps remove lingering odors, heat, and smoke.

Industrial Factories & Workshops

  • Provides cooling in areas where full HVAC is unviable.
  • Controls dust and airborne particles.
  • Improves worker comfort and productivity.

Warehouses

  • Reduces temperature rise during summer.
  • Improves air circulation for stored goods.
  • Prevents musty odors by introducing fresh air.

Other Commercial Uses

  • Auditoriums, malls, event halls, canteens, gyms, printing presses, textile mills,
    etc.

5. Advantages:

  • Cost-effective cooling compared to full air conditioning.
  • Simple design & maintenance.
  • Energy efficient (especially evaporative cooling type).
  • Versatile applications across commercial, industrial, and institutional
    sectors.
  • Improves IAQ (Indoor Air Quality) by introducing fresh, filtered air.

6. Limitations:

  • Evaporative cooling effectiveness depends on outdoor humidity (less effective
    in high humidity areas).
  • Requires regular cleaning to prevent bacterial growth.
  • Water quality must be maintained to prevent scaling or odour.
Feature Evaporative Air Cooling Air Conditioning
Fresh Air Introduces 100% fresh air Re-circulates the same stale air
Windows and Doors Can be left open Must be shut
Moisture Keeps the air moist, great for allergy and asthmatic conditions Reduces moisture, which can be bad for asthma and allergy sufferers
Ventilation Provides full ventilation, exhausts odors and germs Re-circulates odors and germs
Efficiency in Rising Temperatures Increases cooling capacity as outside temperature rises Reduces efficiency and capacity as outside temperature rises
Installation Costs 70% less than the installation costs of air conditioning Costly installation
Running Costs 90% less than the running costs of air conditioning Higher running costs
Feature Single Skin Double Skin
Corner Cast Iron PVC
Sheet Metal 16 G. G.I. 24 G.I. – P.P. Sheet Outside
24 G.I. GI Inside
Insulation No Insulation Puf Insulation (CFC Free)
Base 75/100mm C Channel 75/100mm C Channel
Tank MS / SS MS / SS
Filter Frame G.I. / Aluminium G.I. / Aluminium
Vibration Isolator Cushy Foot Mounting Cushy Foot Mounting
Fan Centrifugal Fan – Forward Curved / Backward Curved Centrifugal Fan – Forward Curved / Backward Curved
Cooling Media Cellulose Pad Cellulose Pad
Air Discharge Horizontal / Vertical Horizontal / Vertical
Air Washer Placement Ceiling Suspended / Foot Mounting Ceiling Suspended / Foot Mounting