Industrial warehouses and logistics distribution hubs across Selangor frequently struggle with extreme indoor heat buildup during Malaysian afternoons. This project case study details how Kpacific engineered an integrated evaporative cooling and positive-pressure ventilation system for a 25,000 sq ft logistics depot in Section 22, Shah Alam, reducing internal ambient temperatures by 7.4°C while saving over 75% on projected electrical running costs.
The Facility Profile & Heat Challenge
The client operates a high-velocity e-commerce fulfillment depot in Shah Alam, Selangor. With over 60 active picking and packing personnel, 8 loading docks, and continuous forklift traffic, the facility faced severe thermal challenges:
- Solar Heat Radiation: The 25,000 sq ft warehouse featured an uninsulated metal-deck roof (8.5m ridge height). By 1:30 PM, solar radiation heated the roof deck to over 58°C, radiating radiant heat directly onto floor staff.
- Extreme Internal Heat: Ground-level temperatures routinely climbed to 37.8°C with stagnant airflow, causing worker heat exhaustion, picking errors, and high turnover rates.
- Airtight AC Quotes Were Prohibitive: Engineering quotes for conventional commercial air conditioning exceeded RM380,000 in capital expense, plus estimated TNB monthly bills surpassing RM18,000/month—completely unviable given the 8 open loading roller shutters that could not be sealed.
For more background on equipment comparisons, see our guide on air coolers vs air conditioners for workplaces.
The Solution Architecture Engineered by Kpacific
Rather than attempting to fight open roller shutters with sealed refrigeration, Kpacific designed a positive-pressure displacement ventilation system combining high-volume fresh-air evaporative cooling with targeted roof exhaust relief:
System Equipment Specification:
• 8 × Rooftop Industrial Evaporative Coolers: Heavy-duty 25,000 m³/h down-discharge units (1.5 kW each), delivering a combined 200,000 m³/h of 100% fresh, filtered chilled air.
• Spiral Fabric Ducting & High-Throw Diffusers: Suspended at 4.2 metres directly over packing tables, sorting conveyors, and order-picking lanes.
• 4 × Heavy-Duty Fiberglass Negative Pressure Exhaust Fans: Installed at the high ridge opposite loading doors to continuously extract hot buoyant air trapped beneath the roof ceiling.
Because the evaporative coolers pump 200,000 m³/h of fresh air into the building under positive pressure, dust and hot vehicle exhaust fumes from outdoor delivery trucks are naturally pushed away from the open roller shutters.
Explore our full line of industrial evaporative cooler specifications and factory installation capabilities.
Measured Project Results: Before vs After Data
Thermal mapping and anemometer measurements taken across 12 monitoring stations over 14 consecutive production days confirmed dramatic improvements:
| Performance Metric | Before Kpacific Installation | After Kpacific Installation | Net Improvement |
|---|---|---|---|
| Peak Working Area Temperature | 37.8°C (stagnant heat) | 30.4°C (continuous breeze) | -7.4°C Drop |
| Air Changes per Hour (ACH) | ~4.2 ACH (natural draft only) | 28.0 ACH | +560% Fresh Air Turnover |
| Relative Humidity at Discharge | 42% – 48% (dry & dusty) | 62% | Optimal comfort range |
| Air Velocity at Workstations | < 0.2 m/s (dead air) | 1.5 – 2.2 m/s | Direct evaporative wind-chill |
| Total Daily Electricity Cost (12h) | ~RM180/day (multiple fan towers) | ~RM29.30/day (all 8 coolers) | Massive energy efficiency |
ROI Realization & Operational Impact
By opting for Kpacific’s evaporative cooling architecture instead of compressor-based commercial AC, the logistics operator achieved:
- RM260,000+ Saved on Initial CapEx: Total turnkey installation was completed under 35% of the capital cost of a ducted chiller system.
- Over RM14,500/Month in Operating Power Savings: Under standard Tenaga Nasional Berhad (TNB) commercial tariffs, running eight 1.5 kW coolers for 12 hours costs approximately RM29.30 per day—or roughly RM760/month for the entire 25,000 sq ft depot.
- 8.5-Month Full Investment Payback: Combined energy savings and a documented 22% decrease in heat-related sick leave allowed the company to break even on the capital investment within 9 months.
Learn more about equipment sizing methodologies in our industrial evaporative cooler sizing and cost guide.
Need a Thermal Assessment for Your Warehouse?
Kpacific’s engineering team provides complimentary on-site thermal mapping, airflow calculation, and duct layout proposals for factories across Shah Alam, Puchong, Klang, and Selangor.
- On-site dry/wet bulb temperature logging
- CFM & Air Changes per Hour (ACH) modeling
- TNB electricity savings projection
- Complete turnkey duct fabrication & install
Or call our engineering desk: +60 1700-818-300