Evaporative Cooling Solutions in Industrial Workshops: How and Why They Work

Industrial workshops can become extremely hot during the summer months, especially when machinery, welding and extraction systems are running for long periods. Excess heat affects employee comfort, productivity and even safety. One of the most efficient ways to maintain a comfortable temperature without the high running costs of traditional air-conditioning is through evaporative cooling.

What is evaporative cooling?

Evaporative cooling uses the natural process of water evaporation to reduce air temperature. When warm air passes through a wetted filter pad, water absorbs heat from the air as it evaporates, producing a flow of cooler air that is then circulated around the workspace.

This process is energy-efficient because it relies on water and air movement rather than refrigeration. The only electricity used is to power the fan and pump that distribute air and keep the pads moist.

For a visual guide to how the process works, the Chartered Institution of Building Services Engineers (CIBSE) provides useful references on natural and mechanical cooling techniques.

Why workshops benefit from evaporative cooling

1. Improved comfort and productivity

High workshop temperatures can cause fatigue, slower reaction times and reduced concentration. Cooler air helps staff remain alert and comfortable, improving overall output.

2. Lower energy consumption

Evaporative cooling can use up to 80 percent less energy than a comparable refrigerated system. It is particularly cost-effective in large open spaces where traditional air-conditioning would be expensive to install and operate.

3. Better air quality

Because the system continually introduces fresh filtered air rather than recirculating the same air, it can help dilute airborne contaminants. When used alongside a properly designed local exhaust ventilation (LEV) system, this combination significantly improves air quality.

4. Environmentally friendly

Evaporative systems do not use chemical refrigerants such as hydrofluorocarbons (HFCs). They therefore have a much smaller carbon footprint and are easier to maintain sustainably.

Key design considerations

When installing an evaporative cooling system in an industrial environment, several factors must be evaluated:

• Airflow requirements – correct sizing ensures that cool air reaches all areas without causing draughts. 
• Water quality – mineral deposits can affect pad performance and lifespan; filtration or water treatment may be required. 
• Placement of units – cool air should flow across work areas and exit through natural or mechanical extraction points. 
• Integration with extraction systems – ensure that airflows from LEV and cooling systems complement each other rather than competing. 
• Maintenance schedule – pads, pumps and filters must be cleaned and inspected regularly to prevent microbial growth or scale build-up. 

For further technical guidance on maintenance and hygiene, see HSE guidance on evaporative cooling and Legionella control.

Integrating evaporative cooling with LEV systems

Many workshops already have dust or fume extraction systems. Introducing evaporative cooling should never compromise these. The two can work together effectively when airflows are balanced. Cool, fresh air drawn in by the cooling units can help replace the air extracted by LEV systems, maintaining a stable and comfortable environment without creating negative pressure zones.

LEV Engineering’s specialists can assess both systems together to ensure they operate efficiently and meet COSHH and HSE recommendations.

Maintenance and operation

An evaporative cooling system will only perform efficiently if it is maintained correctly. Daily and weekly checks should include:

• Confirming even water distribution over pads 
• Cleaning filters and sump trays 
• Checking fan operation and air distribution 
• Inspecting for mineral build-up or microbial growth 

Regular professional servicing ensures hygiene standards are met and prolongs the life of the system.

Why choose a professional installer

Every workshop layout is different. A professional installer can design an evaporative cooling solution that fits your space, process and existing ventilation. Correct design avoids wasted energy and ensures that the cooling effect reaches the areas where it is most needed.

LEV Engineering Ltd supply and install bespoke evaporative cooling solutions for workshops, factories and manufacturing sites across the UK, ensuring optimum performance and compliance.

Contact Us Today

If your facility struggles with heat during the warmer months, consider an evaporative cooling system. Contact LEV Engineering to arrange a consultation and find out how an efficient cooling solution can enhance comfort, safety and productivity in your workshop.