Warehouses demand reliable, efficient thermal control—whether for space heating, process heat recovery, or temperature stabilization for stored goods. A custom industrial heat exchanger allows you to match capacity, footprint, and durability precisely to your facility’s requirements. This guide walks through the end-to-end process of designing and building a heat exchanger tailored for warehouse applications.
Step 1: Define the Warehouse Heating or Cooling Requirements
Start with a clear performance target.
Key inputs to calculate:
- Total square footage and ceiling height
- Insulation values (walls, roof, dock doors)
- Desired temperature range
- Outdoor design temperature
- Internal heat loads (equipment, forklifts, lighting)
Common warehouse applications:
- Space heating using hydronic or glycol loops
- Heat recovery from compressors or industrial processes
- Make-up air heating for dock doors and ventilation systems
A precise BTU or kW requirement ensures your exchanger is neither undersized nor inefficiently oversized.
Step 2: Select the Right Type of Industrial Heat Exchanger
The warehouse environment determines the exchanger style.
Common options include:
- Fin-and-tube heat exchangers – Ideal for air-to-liquid warehouse heating
- Shell-and-tube heat exchangers – Best for high-pressure or high-temperature fluids
- Plate heat exchangers – Compact, efficient for clean fluids
- Air-to-air heat exchangers – Used for ventilation heat recovery
For large open warehouses, fin-and-tube designs are often preferred due to durability, airflow compatibility, and ease of maintenance.
Step 3: Choose Industrial-Grade Materials
Material selection impacts longevity and performance.
Typical material choices:
- Aluminum – Lightweight, excellent heat transfer, corrosion resistant
- Copper – Superior thermal conductivity, common in coils
- Stainless steel – Withstands harsh environments and chemicals
- Carbon steel – Cost-effective for non-corrosive systems
Custom fabrication allows mixed materials—for example, aluminum fins with copper tubes—to balance performance and cost.
Step 4: Engineer for Airflow and Fluid Flow
Proper airflow and fluid dynamics are critical.
Design considerations:
- Fan CFM requirements
- Static pressure limitations
- Tube diameter and wall thickness
- Flow rate and pressure drop
- Freeze protection for cold climates
Warehouses often require high-volume, low-resistance airflow to maintain even temperature distribution across large spaces.
Step 5: Custom Fabrication and Assembly
Once engineering is complete, fabrication begins.
Custom fabrication may include:
- Precision-bent tubing
- Brazed or welded joints
- Custom mounting brackets and frames
- Protective coatings for corrosion resistance
Building a custom unit ensures the heat exchanger fits existing ductwork, mezzanines, or rooftop units without costly structural changes.
Step 6: Testing and Quality Control
Before installation, every custom industrial heat exchanger should be tested.
Testing procedures include:
- Pressure testing for leaks
- Airflow resistance checks
- Thermal performance validation
- Visual inspection of welds and joints
Testing guarantees reliable performance once installed in the warehouse environment.
Step 7: Installation and Integration
Proper installation maximizes efficiency and service life.
Installation best practices:
- Ensure adequate clearance for maintenance
- Use vibration isolation where required
- Integrate with existing HVAC or process systems
- Confirm controls and sensors are properly calibrated
Custom-built heat exchangers simplify installation by matching exact site requirements.
Benefits of a Custom Industrial Heat Exchanger for Warehouses
- Optimized heating and energy efficiency
- Reduced operating costs
- Improved temperature consistency
- Longer service life than off-the-shelf units
- Designed to handle industrial wear and tear
Why Choose a Custom-Built Solution Instead of Off-the-Shelf?
Off-the-shelf heat exchangers are designed for general use. A custom industrial heat exchanger is engineered specifically for your warehouse’s size, airflow, and operating conditions—delivering better performance, fewer modifications, and lower long-term costs. Contact Southpointe Radiator today for any custom fabrication needs.