Configuring an air conditioning system for a 1,000 square meter (approximately 10,700 square feet) factory is a complex engineering task that requires balancing technical specifications, operational needs, and budget constraints. An improperly designed system will lead to excessive energy costs, inadequate comfort, and premature equipment failure. Here is a professional, step-by-step guide to planning the optimal AC configuration.

Phase 1: Critical Preliminary Assessment

Before considering any equipment, a detailed site and needs analysis is mandatory.

1. Primary Function & Occupancy:Activity Level: Is it light assembly, precision electronics, heavy machining, or warehouse storage? Each generates vastly different internal heat loads.Occupant Density: How many workers are typically present? A person can generate 100-300 Watts of sensible heat and latent heat (moisture).Process Heat Load: This is often the largest factor. Catalog all machinery, furnaces, compressors, and processes, noting their power ratings (kW) and operational schedules.
2. Building Envelope & Layout:Ceiling Height: Critical for calculating air volume. A 1,000 sqm factory with a 5m ceiling has a volume of 5,000 cubic meters, while one with a 10m ceiling has 10,000 cubic meters—doubling the capacity requirement.Insulation & Construction: Are walls and roofs insulated? What are they made of (metal, concrete)? Large window areas or skylights introduce significant solar heat gain.Air Infiltration: How often are large doors (loading docks) opened? This introduces outside air that must be conditioned.
3. Environmental Requirements:Temperature & Humidity Setpoints: Does the production process require strict control (e.g., 22°C ±1°C, 50% RH ±5%) or is general comfort cooling (e.g., 26-28°C) sufficient?Air Quality: Is filtration for dust, fumes, or particles needed? Is there a requirement for fresh air ventilation per local occupational health codes (e.g., 30 cubic meters per person per hour)?

Phase 2: Calculating the Cooling Load

This is the cornerstone of the project. Do not rely on rules of thumb. A professional HVAC engineer should perform a Manual J (or equivalent) calculation, which sums all heat gains:

• Sensible Load: Heat that raises air temperature (from sun, roof, walls, people, machinery, lights).
• Latent Load: Moisture that must be removed from the air (from people, processes, outside air infiltration).

Rough Estimation (for preliminary brainstorming only):
For a typical factory with moderate machinery heat and 3-5m ceiling height, a general range is 150-300 Watts per square meter.

• Low-load scenario (warehouse, light assembly): ~150 W/sqm → Total ~150 kW
• Medium-load scenario (general manufacturing): ~225 W/sqm → Total ~225 kW
• High-load scenario (plastics, foundries, dense packing): 300+ W/sqm → Total 300+ kW

These numbers are illustrative. A proper calculation is non-negotiable.

Phase 3: Configuration & Zoning Strategy

• Zoning: Divide the factory into logical thermal zones based on:Sun exposure (north vs. south side).Process heat density (welding area vs. assembly area).Occupancy schedules (day shift vs. 24/7 areas).
• Air Distribution: Use a combination of ducted systems for offices/controlled areas and energy-efficient evaporator units (like ceiling-mounted cassette or ducted units) for the open floor. Ensure even airflow to prevent hot spots.
• Ventilation: Integrate a Dedicated Outdoor Air System (DOAS) or energy recovery ventilators (ERVs) to handle fresh air requirements efficiently, pre-conditioning incoming air to reduce the load on the main AC.

Phase 4: Key Specifications & Modern Features

• Efficiency: Demand inverter/variable-speed compressors. Look for high IEER (Integrated Energy Efficiency Ratio) ratings.
• Controls: A centralized Building Management System (BMS) is ideal. It allows for scheduling, remote monitoring, fault alarms, and data logging to optimize performance.
• Refrigerant: Choose systems using lower-GWP refrigerants like R-32 or new HFOs (e.g., R-513A) for better environmental performance and future-proofing.
• Redundancy: For critical processes, consider splitting capacity across multiple independent units so the failure of one doesn't halt production.

Phase 5: Implementation Roadmap

1. Hire a Professional: Engage a qualified mechanical engineering firm or HVAC contractor with industrial experience.
2. Conduct Detailed Load Calculation: This is the foundation of the design.
3. Design & Quotation: The professional will provide a system design, equipment selection, layout, and a detailed quote.
4. Consider Total Cost of Ownership (TCO): Evaluate upfront cost vs. 10-year energy and maintenance costs. Efficient systems often have a faster ROI than expected.
5. Professional Installation & Commissioning: Proper installation, including refrigerant charging, duct sealing, and electrical work, is crucial. Final commissioning ensures the system operates as designed.

Conclusion

Configuring AC for a 1,000 sqm factory is not about simply buying enough "tons" of cooling. It is a holistic process that starts with a deep understanding of your facility's unique thermal profile and operational needs. By investing in a professional load calculation, selecting an appropriately efficient and flexible system type (like a VRF or zoned ducted system), and prioritizing proper installation and controls, you will achieve a solution that ensures worker comfort, protects processes, minimizes energy expenses, and provides reliable performance for years to come.