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Volkswagen Group, Europe's largest automobile manufacturer, operates production sites across seven European countries. Through their comprehensive "Strategy 2025" program, Volkswagen pursues sustainable mobility while maintaining responsible environmental stewardship.
Rising energy costs and environmental regulations drive automotive manufacturers toward advanced ventilation solutions. Complex assembly processes generate substantial heat loads while needing to meet precise temperature standards, so traditional ventilation systems often consume excessive energy while failing to meet sustainability targets.
Measurable performance improvements
Compared to previous installations through advanced component integration
New air handling units weigh 30% less than conventional alternatives
Reduced footprint simplifies installation and reduces structural requirements
ZerAx® axial fans achieve up to 92% efficiency with industry-leading technology
Systematic evaluation delivers validated performance
Beginning in early 2017, Volkswagen initiated comprehensive technical evaluations of high-efficiency axial fans. This systematic approach focused on verifying real-world performance under demanding production conditions.
The evaluation framework combined extensive testing protocols with precision measurement systems. Performance analysis monitored energy consumption and airflow efficiency in real time, providing quantifiable data for decision-making. Practical trial implementations validated performance projections through pilot installations, while cross-facility benchmarking enabled comparative analysis between different production environments.
By early 2018, Volkswagen deployed these findings at Porsche in Stuttgart/Zuffenhausen, and Volkswagen Navarra in Pamplona, Spain. The measurable results demonstrated clear efficiency gains across multiple metrics.
Technical implementation details
Project scope encompasses comprehensive ventilation system replacement across six air handling units. Trubel Klimatechnik manufactured the units for installation at the Pamplona facility in Spain. The system includes three units operating at 80,000 m³/h each and three additional units handling 60,000 m³/h each, delivering a total capacity of 420,000 m³/h.
The production facility required complete ventilation system renewal, but multiple engineering constraints created complex installation requirements. Insufficient installation area within existing building infrastructure limited conventional placement options. Higher air volume requirements for expanded production operations increased capacity demands, while load-bearing constraints affected equipment placement possibilities. Operational continuity requirements meant minimising production disruption during installation phases.
The technical team identified an optimised roof-mounted solution that addressed these challenges systematically. This approach positioned the large 80,000 m³/h units on a specially designed steel platform connecting two buildings, maximising available space while ensuring structural integrity.
The collaboration with Volkswagen Navarra required precise integration of highly efficient axial fans within next-generation air handling units. Installation proceeded according to strict automotive industry standards, ensuring compatibility with existing production systems. The final deployment, completed in mid-December, exceeded all performance expectations.
ZerAx® axial fans represent current industry-leading technology, achieving fan efficiencies of up to 92%. For this automotive application, the ZerAx® technology was optimised to ensure seamless air handling unit integration while maintaining operational reliability across varying production demands.
The EC+ concept, developed through strategic partnership with Danfoss Denmark, optimises the complete integration of fan, motor, electronics, and diffuser components. This systematic methodology ensures maximum efficiency through precise component coordination, because each element operates synergistically to deliver measurable performance improvements.
Advanced component integration delivers superior performance through systematic optimisation. All devices feature two parallel supply and exhaust fans, providing redundancy and operational flexibility. Newly developed diffusers, measuring 1.5 x Diameter, were optimised for free outlet conditions, maximising airflow efficiency. New EC motors deliver up to 31 kW power while incorporating the Danfoss EC+ concept for intelligent control.
Advanced component technology delivers quantifiable benefits across all operational parameters, with each element exceeding industry-standard efficiency levels:
- Axial fans operate at up to 92% efficiency
- EC motors deliver up to 31 kW power with efficiencies reaching 96%
- Frequency inverters optimised for EC motors achieve up to 98% efficiency
- Diffusers newly developed and optimised for free outlet conditions
Technology fully meets all expectations
Volkswagen Navarra demonstrates leadership in sustainable ventilation technology implementation. Their commitment to environmental responsibility, safety, and efficiency drives continuous energy consumption reduction and associated CO₂ emission decreases. This strategic focus led to selecting the new ZerAx® axial fan technology for assembly hall ventilation renewal.
The demands placed on building air conditioning increase steadily. Axial fans make significant contributions to combining technical requirements with sustainable building design. This trend-setting AHU technology has fully met all expectations.
Proven methodology supports automotive manufacturers
The automotive industry collaboration delivers quantifiable improvements through systematic component integration and optimal technology transfer. Comprehensive knowledge sharing throughout project phases ensures successful implementation, while minimal disruption to existing production schedules maintains operational continuity. Thorough testing protocols verify efficiency improvements before full deployment, and ongoing technical assistance provides long-term support and system optimisation services.
This proven methodology supports automotive manufacturers pursuing efficiency improvements and sustainability objectives. Schedule a consultation to discuss how advanced axial fan technology can optimise automotive facility ventilation systems. NOVENCO engineering experts provide comprehensive technical support.
