Needing to follow the customer and end-user’s pre-defined specification, in addition to a small installation footprint, our engineers built the four bespoke fans at our Fareham-based factory. When building the 1,120mm diameter, stainless-steel long cased axial units, we knew durability was a top priority. We made sure they could withstand the harsh offshore salt-laden environment by using marine-grade aluminium impellers, stainless-steel 316L casings, terminal boxes and ancillaries.

Along with being durable, a key requirement was making sure the fans were explosion-proof and complied with the customer’s design requirements, in addition to offshore and Brazilian safety regulations. As such, the fans were built with C5M-painted Zone 1 ATEX motors, BFOU cabling, and stainless-steel glands. To comply with the Brazilian standard NR-37, motor cowls, access doors, and internal terminal boxes were painted to colour RAL 2008.

For the end-user’s monitoring requirements, the fan models came equipped with Shock Pulse Monitoring (SPM) sensors and a cable transit system to wire the coaxial cable to an externally fan mounted terminal box. Accounting for vibration during installation, the fan mounting plate was paired with anti-vibration mounts.

Leading on the project, Lewis Brand, Technical & Project Sales Engineer at Elta, said:

“Working on applied technology projects means working through customer specifications to ensure we’re designing the best fan for their application, and working with customers throughout a project is something we pride ourselves on at Elta. This project really showcases our engineering capability; four unique fans that we have manufactured to the highest quality and will stand the test of time.”

Find out more about our Applied Technology division and ATEX fans!

Do you have bespoke project requirements? Contact us today.

Modern Methods of Construction and offsite initiatives are growing exponentially across the UK. To highlight this, earlier this year, the Crown Commercial Services selected 29 firms to be part of the £10bn Offsite Construction Solutions framework, with public sector buildings across healthcare, education, justice and defence all expected to swing toward modular construction.

Our Prefabricated Solutions service is an ideal solution for specifiers and contractors working on commercial building projects of any scale. Fans and ancillaries, such as acoustic equipment, mounts, panels, flexible connections, fan controls and more, can all be assembled offsite and delivered as a compliant assembly, ready for crane lifting that results in quick, efficient installation. The ventilation and air movement manufacturer is one of the first in its sector to offer this across its entire range of fans.

Colin Moss, Car Park & Smoke Control Manager, has pioneered the service and elaborates on the multiple benefits specifiers and contractors can gain by going down the prefabricated assembly route. He said: “Installing individual components on-site can be a cumbersome and time sensitive task. It requires ample storage and working space, leading to congestion on busy sites and increasing the potential for site safety issues. The collection and assembly of various parts can also be time-consuming, causing delays to projects.

“Not only this, but site time is costly, and labour costs can quickly add up when dealing with unnecessarily complex, site installations. With Prefabricated Solutions by Elta, these challenges are a thing of the past, and you can manage these expenses and have better quality control of the finished product.”

A key benefit of the new service is the provision of sound and performance data associated with acoustics ancillaries. For all acoustics components in the fan setup, acoustic performance data is also supplied at the initial stages from our Noise Control Specialists to help simplify the process for specifiers and contractors, so they do not need to re-select or re-calculate separately were they sourcing these components from elsewhere.

This service means units are built to the highest standards within a controlled factory environment. We hold ISO 9001 accreditation for quality management, guaranteeing that finished products are reliable, durable, and ready on time.

Luke Hammond, Applications Specialist (Smoke and Fire), explains that prefabricated assembly of fans also unlocks a host of other benefits. These include a more streamlined design process, offering simpler compliance with both ‘The Golden Thread’ and environmental requirements while reducing disruption to the local community, and other related site activities.

“Gone are the days of waiting for single components to be delivered to the site, which can get lost or damaged while other elements of the project are in transit. With our Prefabricated Solutions service, all necessary components are packaged together, ensuring a hassle-free delivery,” said Luke.

“Preassembled units also mean other costly, disruptive activities on-site, such as crane lifting and road closures, can be minimised. Shipping materials like pallets, packaging and strapping is all reduced as well, and with better overall coordination, Prefabricated Solutions allows workforces to focus on boosting productivity in other areas.”

For more about our Prefabricated Solutions service, visit eltauk.com/prefabricated-solutions

The CCC states the industry lacks urgency in its pace of reaching 2050 targets and needs more help to decarbonise its operations. It stresses the importance of establishing UK Environmental Reporting Guidelines and the Net Zero Transition Plan Standard, both of which will set it as a requirement for businesses to disclose the use of carbon credits.[1]

On top of that, the industry is being encouraged to take action in decarbonising building solutions to futureproof construction for future generations. David Millward, Elta Group’s Product Manager, highlights the importance of collaboration in the supply chain within the construction industry.

“The CCC’s latest report is quite damning in that we’ve lost our global leadership position on climate matters. The report show that planning policies need radical reform, and all decisions must be taken with full regard to the imperative of hitting net zero.”

“Given this, all parties need to come together in order to ensure environmentally responsible choices are being made across all operations. From a ventilation and air movement perspective, carbon emissions can be easily minimalised if specifiers, contractors and manufacturers work together. At Elta, we’re making this one of our critical priorities, and have already moved to release TM65 Embodied Carbon reports, aligned to CIBSE’s methodology, to help specifiers and contractors better compare construction components and opt for most sustainable solutions.”

We’re pioneering the industry toward Net Zero as it becomes one of the first to offer TM65 Embodied Carbon reports for its fans and building services products. Created by CIBSE (the Chartered Institute of Building Services Engineers) in 2021, it is a calculation methodology that helps assess how much embodied carbon is associated with products.

“The reports are calculated through a number of variables such as material weight and assesses the embodied carbon generated at each stage of a product’s lifecycle,” said David. “This includes going from production to manufacturing, through to transportation, maintenance while in-use, and end-of-life recyclability potential. A key benefit is it helps make it easier to compare products against each other based on the amount of carbon they release in their production through to end-of-life,”

“The working model of TM65 Embodied Carbon reports supplies the construction chain with carbon credit insight to follow regulations and minimise negative environmental impacts, leading the industry towards opting for more eco-friendly design solutions.”

“It is of the highest importance for the supply chain to utilise the available resources to adequately specify building and ventilation solutions. Collaboration is key to meeting the urgent decarbonising responsibilities towards net zero targets.” concludes David Millward.

Join the movement towards Net Zero! Contact us today for information on our TM65 carbon reports and explore Elta’s ventilation solutions and range of products.

[1] https://www.theccc.org.uk/publication/2023-progress-report-to-parliament/#intro

The importance of procuring the right fan and impellers for the application cannot be understated. Without careful consideration, a host of issues can happen, including reduced lifespan, higher costs from servicing and maintenance, as well as lost operating time and money through unnecessary downtime. The fan may also perform at lower capacity, resulting in higher energy costs. To ensure these detriments do not occur, impellers must be accurately designed, specified and manufactured.

Design and specification

Impellers (and fans) must always be specified in line with customer requirements. There are numerous conditions to be considered during this process, including necessary air volume and pressure, air density and temperature ranges they need to work to. Any other operational conditions such as ATEX (hazardous, explosive materials) or smoke ventilation can affect selection, and should therefore be factored in as well. Indeed, for ATEX applications, impellers must be tested and certified to be anti-static, as any sparking can cause explosions – here ATEX fans must be used.

Navigating these parameters is evidently a meticulous process, which is why we offer a Fan Selection Programme for greater ease. Users are able to determine the correct impeller for their application requirements through airflow, pressure, sound and efficiency requirements. Impeller stress calculations are also built into the programme to ensure safe selections.

Once all elements have been determined, ventilation professionals can select the appropriate impeller and design the correct fan in line with customer needs. Different types of blades should be considered, depending on the required application. For example, in marine environments, glass reinforced plastic, certain grades of aluminium and anti-static impellers could be suitable. Across all material choices it’s important that blade design incorporates adjustable pitch and solidity for a wider range of options.

Coating and resistive properties should also be appropriately decided to provide an effective solution. In specific applications where impellers need additional protection, they can be painted, flame sprayed or anodised to prevent corrosion or wear and tear.

If impellers, and fans themselves, are incorrectly specified, then the units can produce more noise than necessary or be less efficient at moving air. This then leads to unwanted noise pollution, higher energy costs, and ultimately, the ventilation system is not performing as required.

Performance testing and quality control

Once an accurate specification has been agreed, it is important that quality and performance is guaranteed in the subsequent manufacture process. Here, the critical measure is what factory production controls are in place to provide assurance that all fans built are being run-tested to check for vibration, running current, and speed. Thorough testing is vital to achieve optimum performance and should be carried out in line with applicable regulations. Ventilation specifiers should look to fan suppliers that test in accordance with key industry standards, such as BS ISO 5801.

Acoustics and airflow are also key factors to accommodate. The principal standards to adhere to are air performance (ISO 5801 and AMCA 210) and sound (ISO 13347-2, ISO 5136, AMCA 300), for which all impellers should be fully tested to. Third party testing is also a key sign of quality, and here at Elta, testing is performed in our own laboratory which is accredited by AMCA for performance and sound. The option of customer witness testing can also provide added peace of mind here.

Alongside the testing of the individual components, when building the fan, impellers need to be dynamically balanced to operate correctly and thus prevent vibration back to the fan, motor, bearings, and surrounding structure. Again, regulatory testing must be conducted to meet the conditions of ISO 14694, along with providable certificates for credibility.

Well-suited solutions

For any application, preventing downtime and unnecessary maintenance is a key part of ensuring optimum performance. To maximise lifespan, it is therefore paramount that impellers are carefully considered as part of fan systems. By applying design and specification principles in tandem with performance testing and quality assurance, the right solution can be achieved.

With many years of experience in supplying fans for a range of applications, our technical team can impart the necessary expertise and knowledge to accurately specify a wide range of commercial, industrial and hazardous applications. Our own Axial Impeller technology is the heartbeat of many of our products, click here to learn more!

Why is this boost needed?

With the construction industry tackling a balancing act of declining budgets alongside improved sustainability and safety targets, the need for an all-round solution is greater than ever.

What has Elta done?

Having gained compliance with BS EN12101-3:2015, the fans are now capable of being powered through a VSD in times of emergency. Incorporating the VSD with the fan itself has meant system specifiers and designers are now offered a more streamlined approach. By testing the high-performance smoke fans in conjunction with various VSDs, this has ensured that the two can be used together without the need for bypassing or fitting filters to the VSD in fire mode. Using the VSDs alongside Elta’s impellers has also increased the efficiency of the system, and thanks to the completion of the BS EN12101-3:2015 testing, allows for a fully compliant and highly efficient holistic solution.

Where will we see the benefits?

With urbanisation growing across Europe, the need for space-saving has led to the construction of more mid-rise to high-rise buildings. In turn, this is driving an increase in demand for high-performance equipment compliant with strict government regulations to ensure the safety of all people and property.

While there are different ways to ensure the systems do this, the most efficient way is to have the fans and VSDs tested together, hence why Elta now has the BSI accreditation.

Elta are committed to conforming to the highest standards, and as a result hold a number of additional accreditations alongside this BSI certification. 

The division designs, manufactures, and supplies fans for a variety of specialist OEM applications, including power generation, offshore oil and gas, agriculture, and marine. Capable of delivering both standard and bespoke products, the company utilises expert knowledge and the latest technology to develop solutions for customers across the globe. The Fareham site processes raw materials to produce fan casings and ancillaries, before assembling them and selling to these customers.

The first new machine is the Bystronic Xact Smart 100, which replaces a 1975 press brake and represents an investment of over £60,000. The old machine operated on one axis, which meant that more set ups were required to fold parts. The age of the machine also meant that wear and tear could potentially reduce the quality of the output, which was the primary motivation behind investing in a replacement.

The function of the Bystronic Xact Smart 100 is to fold metal – a critical part of the Sheetmetal process. Elta’s Applied Technology is a global leader in bespoke fan manufacturing, and the Sheetmetal department has been an integral part of the plant’s ability to support a wide range of sales markets.

The machine benefits from quicker setup times, and significantly improves on the usability of its predecessor. Combined with enhanced reliability, the Bystronic Xact Smart 100 has increased the output capabilities of the Fareham-based plant significantly.

Matt Targett, Operations Manager at Elta, comments: “We are dedicated to investing in modern technology, both in order to maximise our current capabilities, but also to develop better products. We know that our specialist factory is a key selling point for customers, and purchasing new machines provides the opportunity to up-skill our workforce, and ultimately improve staff morale.”

Another addition to the Fareham site is a new jig, which is used to help assemble 2 metre hub impellers. Quality impeller manufacture and assembly revolves around precision, with consistency of blade angles directly relating to a fan’s operational efficiency. The introduction of a pneumatic jig means that blade angles no longer have to be set by hand, which is a significant benefit given the numerous variations of impellers that are manufactured at the site.

The new jig, which is used by those trained in building 550mm hub impellers, will also help to increase capacity in the 2m impeller market, exploiting the pneumatic design to drive improvements in method. It was introduced at an investment of almost £20,000, but as Matt Targett concludes, investments such as these are made with the future in mind:

“We are committed to investing in new equipment, especially if it will benefit our customers in the long-term. We are immensely proud of our ability to produce unrivalled products, utilising the latest technology in order to meet our customers’ demands. Our Sheetmetal setup has been tremendously successful, and has even been replicated at other plants in Elta Group across the globe.

“The introduction of a new jig and the Bystronic Xact Smart 100 are indicative of our innovative approach, and have ensured that our operation remains at the cutting edge moving into the future. We are very excited to see how they improve our capabilities over time.”

For more information on Elta Applied Technology, please visit: https://eltauk.com/divisions/applied-technology/

Following a series of standard test methods and procedures, the laboratory of Elta has been accredited by AMCA International as being qualified to conduct tests in accordance with ISO 5801. In addition, the manufacturer’s Axial Fans, ranging in diameter from 315mm to 2000mm, are now licensed to bear the AMCA seal. The performance ratings include information on how the product was tested and what appurtenances (accessories) were included during the ratings tests, allowing for the correct specification of air system components.

AMCA International is an American-based non-commercial organisation which independently tests and certifies ventilation technology for industrial, commercial and residential markets. While AMCA isn’t always a requirement in the UK, its Certified Ratings Program (CRP) is recognised across all industrialised regions and is of particular importance in countries such as America, India, and Malaysia.

Alan Macklin, Group Technical Director of Elta Group comments, “By working with an AMCA-approved manufacturer like ourselves, buyers, specifiers and end-users can benefit from peace of mind that our performance ratings are reliable and accurate. What’s more, it provides a great way for industry to compare the performance of manufacturers’ products via an impartial authority.”

The installation of a five tonne, twin hoist crane from British manufacturer Kone Cranes is providing a boost in production capacity and work flow at the plant, especially in the production of the larger and heavier fans. The growth in large bespoke units too is also a factor in the decision to invest in the new crane.

Larger and more awkward fan units, some weighing up to 3.5 tons, are processed in a safe and efficient working environment, which has been positioned away from some of the busier areas of the factory. Inside the plant the flow of work has been significantly improved following the commissioning of the new crane. Fans are now shipped quickly from the assembly area to the packing area and swiftly out for delivery to customers.

There is also positive news at the smaller end of the Elta market with new hubs being introduced. The new hubs bring extra efficiency and capability to the Elta impeller range. Elta’s latest addition is the ‘Series 1′ impeller blade.

This range offers three different hubs covering 12 duct sizes, nine blade combinations and variable pitch to enable the selection of the most efficient combination for each duty. The new range is also significantly stronger than its predecessor allowing use in more demanding applications.

These latest investments at Fareham are part of progressive modernisation and follow the installation of a seam welder in the sheet metal area in 2013. Speaking about the latest investment, Damian Buxton, Managing Director of Elta Applied Technology said: “Our planning and investment centres on our customers’ needs and our ability to match increased demand with efficient production.”

The ‘Africa Mercy’ operates in hot and humid climates in Africa making it challenging to keep the medical spaces cool, this is particularly difficult in the CAT scanner room. Adding to this problem, in 2013 Mercy Ships installed a new CT scanner which produces a lot more heat than the older model. To adequately remove the heat build up and bring in cooled air, a more powerful fan was required.

Sales Engineers at Elta produced three viable options and presented them to Mercy Ships’ procurement manager, Steve Cook. Mr Cook and his engineering team decided on Elta’s Viper, inline centrifugal fan SCC350-1AC. After learning more about the charitable work Mercy Ships does throughout the world, as well as the time and services given up by the medical professionals, Elta decided to donate all of the equipment free of charge to help further support the charity’s operations. The ‘Africa Mercy’, operated by Mercy Ships is the world’s largest civilian hospital ship, providing free healthcare services to those living in developing countries, where the services of professional medical staff are needed most.

The ship is currently docked in Madagascar, one of the world’s poorest countries, with only two physicians and three hospital beds available for every 10,000 people. To many thousands of people, Mercy Ships represents the difference between life and death. The ‘Africa Mercy’ started life as a Danish rail ferry and was subsequently converted into a hospital ship with six operating theatres and recovery rooms.

The crew are all volunteers bringing their expertise as surgeons, doctors, nurses, dentists, engineers, caterers and cleaners. Not only do they volunteer, they also have to raise their own funds through sponsorship in order to serve. Commenting on the contribution from Elta, Steve Cook said “With this great donation we can ensure that the environment for the medical staff and patients will be more pleasant. It will also add to the longevity of this critical piece of medical equipment for the service it provides.”

He will also continue reporting to the Elta Group board on activities at the company’s Building Services Division in Kingswinford, West Midlands. Damian’s promotion is in keeping with the Group’s values based on the belief in its personnel to grow. Indeed, the Group aims to promote from within wherever possible, except when an outside infusion is needed or obviously preferable.

Damian is a graduate of Middlesex University where he gained a BA (Hons) in Accounting and Finance in 1990, joining Elta seven years later in 1997 in the role of Financial Controller. Progressing through the company, he qualified as an Associate Member of The Chartered Institute of Management Accountants (ACMA) in 2003. In 2008, in recognition of his unstinting commitment to the company, he was promoted to Finance Director. Former Managing Director, Mr. David Osgerby, left the company in order to pursue other business interests. Following his departure, Damian was asked by the Elta Group board of directors, to coordinate activities temporarily across both the Fareham and Kingswinford facilities.

During this three month period, the board has carefully evaluated a number of key considerations that will have an influence on how the structure of the company is shaped in the future. Damian is based at the company’s head office in Fareham, but will continue to liaise and work closely with management teams from both sites. He will involve himself in all aspects affecting the business strategy and performance of the two sites. Following his appointment as MD, Damian will continue to build upon his responsibilities, providing the Elta Group with focus and commitment in the interests of its longer term objectives. He will actively contribute in developing stronger communication between the Fareham fand Kingswinford sites, having responsibility for the coordination of management meetings across both divisions. He will be fully engaged in strategic and operational developments, reporting regularly to the board on the ongoing business strategy and performance of Elta.

In view of the additional responsibilities that Damian will be assuming and the change to his role within the company, he will be assisted by colleague, Joanne Morgan who, in turn, is being promoted to Financial Controller. She will continue reporting to Damian on all financial matters across both sites.