Cooling factory halls, workshops and warehouses

“Cooling 5 workplaces was much simpler and more cost-effective than cooling our entire production warehouse. And, in addition, I can turn it on or off as needed. Adding 2 workplaces was also a piece of cake.”

Larry Oldfield — Chief Production, Extrusion Plant Harderwijk

The Challenge: Cooling Large Industrial Spaces

Cooling factory halls, workshops and warehouses with conventional air conditioning is virtually impossible — or simply unaffordable. The volumes are too large, the heat sources too intense, and the energy costs too high. A 10,000 m² production hall simply cannot be cooled the same way as an office.

High-pressure water misting — also known as adiabatic cooling — offers a proven, scalable alternative. Water is pressurised to 70–120 bar and forced through precision nozzles, creating an ultra-fine mist that evaporates instantly. This flash evaporation absorbs heat from the surrounding air, reducing the ambient temperature by 5 to 9°C depending on humidity conditions.

The calculation is straightforward: 1 litre of water = 650 watts of cooling capacity. For a fraction of the energy and investment cost of conventional air conditioning, high-pressure misting delivers immediate, measurable results.

Key Advantages for Industrial Environments

• Low investment cost — a fraction of the cost of industrial air conditioning systems
• Low running costs — minimal water and electricity consumption
• Scalable — cool individual workstations or entire warehouse floors; expand at any time
• Fast installation — most systems installed within 1–2 days by any technical service team
• No wet surfaces — droplet size below 10 microns evaporates before reaching people or equipment
• Dual function — simultaneous dust suppression and cooling in production environments
• 24/7 reliability — high-pressure systems from our Italian factories, 38+ years of engineering experience

How Much Can You Save? A Real-World Cost Comparison

The business case for high-pressure misting in industrial environments is straightforward — but the numbers vary significantly depending on the size of the space and the heat load involved.

For a typical production hall of 3,000–5,000 m² with 30–50 workers on the floor, the comparison looks like this:

Conventional industrial air conditioning for a space of this size requires chillers, ductwork, distribution units and electrical infrastructure. Capital investment typically runs to €200,000–€500,000. Annual energy costs for cooling alone add €30,000–€80,000, depending on climate and operating hours.

High-pressure misting takes a different approach: rather than cooling the entire building volume, systems are zoned to cool the workstations where people actually work. A basic workstation cooling setup for 5–10 positions starts from around €3,000. A full multi-zone system covering 20–40 workstations across a large production floor typically runs €8,000–€15,000 installed. Annual energy and water costs are well below €2,000.

The system cools the people and processes that matter, not the air above 8 metres of ceiling. Payback periods of 12–24 months compared to conventional cooling are common. In many cases the decision is not “misting vs. air conditioning” but “misting instead of doing nothing” — because full air conditioning was never financially viable in the first place.

Request a tailored cost comparison for your facility: +31 85 273 3970 | info@fogsystems.eu

Sector Spotlight: Aluminium & Metal Extrusion Plants

Metal extrusion and processing plants present one of the most demanding cooling challenges in European industry. Extrusion lines generate sustained radiant heat — workers at handling and inspection stations can be exposed to ambient temperatures of 38–45°C during summer production runs.

High-pressure misting systems have been installed in extrusion facilities across the Netherlands, Belgium and Germany, including Hydro Extrusions — one of the largest aluminium producers in Europe. Nozzle lines are positioned above workstations along the extrusion run, with independent zone controls allowing operators to activate cooling for specific stations as needed.

The key advantage in extrusion environments is the absence of wet surfaces: at 70–120 bar, droplets below 10 microns evaporate completely before reaching hot metal, aluminium profiles or the workers handling them. No condensation, no interference with surface quality, no slippery floors.

Sector Spotlight: Logistics, Warehouses & Distribution Centres

European health and safety legislation increasingly recognises heat stress as a workplace hazard. The Dutch Arbowet, German ArbStättV and UK HSE guidance all require employers to take reasonable steps to manage thermal comfort — and enforcement action for failure to act is increasing.

For logistics and distribution centres, the challenge is twofold: the buildings are large open volumes that absorb solar heat through the roof, and loading dock doors open and close throughout the day, constantly introducing hot outside air in summer.

High-pressure misting at loading dock entrances and above picking zones provides targeted cooling without the need for building-wide air conditioning. Systems are typically zoned by activity area — dock doors, sortation lines, packing stations — and controlled by thermostats that activate cooling automatically when temperatures exceed the set threshold.

Several major European logistics operators have standardised misting systems as part of their summer heatwave response protocols, with systems deployed across multiple sites from the same supplier.

Heat Stress & Legal Compliance

Beyond productivity and comfort, workplace heat stress carries legal and liability implications for European employers. The EU Framework Directive 89/391/EEC requires employers to assess and mitigate all workplace risks — including thermal risk. National implementing legislation in the Netherlands (Arbowet), Germany (ArbStättV) and Belgium (Codex Welzijn op het Werk) all contain enforceable provisions on thermal working conditions.

High-pressure misting is recognised by occupational health authorities as an effective engineering control for workplace heat — alongside ventilation and shading. Documenting a misting installation as part of your risk assessment demonstrates proactive compliance and reduces exposure to enforcement action, insurance claims and reputational risk in the event of a heat-related incident.

Our team can provide technical documentation suitable for inclusion in occupational risk assessments (RI&E in the Netherlands, Gefährdungsbeurteilung in Germany).

Applications Across Industry

High-pressure misting systems from Fog Systems Europe are used in a wide range of industrial settings across Europe:

• Aluminium & metal extrusion plants — trusted by Hydro Extrusions and other major European producers
• Logistics & distribution warehouses — cool loading docks and picking zones
• Food & beverage production — temperature-controlled environments without moisture contamination
• Automotive workshops — bodyshops, paint preparation areas, assembly lines
• Printing & packaging — humidity control combined with cooling for paper and film handling
• Livestock farming — cooling of pig, poultry and cattle housing for improved welfare and productivity
• Waste processing & recycling plants — dust suppression combined with odour control

System Specifications

• Operating pressure: 70–120 bar
• Droplet size: < 10 microns (flash evaporation, no wet surfaces)
• Cooling effect: 5–9°C ambient temperature reduction
• Water consumption: approx. 1–3 litres per nozzle per hour
• Pump range: single-phase (230V) for small installations up to 3-phase (400V) for large industrial systems
• Control options: hygrostat, thermostat, climate computer, timer — fully automated operation
• Warranty: 2 years on all components

From Idea to Installation in 4 Weeks

Our experienced team of engineers will size the system to your specific space, heat load and humidity conditions. Systems are designed for installation by your own technical team — no specialist contractor required. Full documentation, installation guides and video support are provided as standard.

We ship from warehouses in the Netherlands and Italy directly to your location across Europe. Delivery within 5–10 working days for standard systems.

Frequently Asked Questions

Will the mist make floors and equipment wet?
No. At 70–120 bar, water droplets are smaller than 10 microns — they evaporate completely in the air before reaching any surface. Workers and equipment stay dry.

How much does a system cost?
A basic workstation cooling system starts from a few hundred euros. Full warehouse installations are sized individually — contact us for a tailored quote based on your floor area and heat load.

Can the system be expanded later?
Yes. All our systems are modular. Adding extra nozzle lines or a second pump zone is straightforward — as Larry Oldfield noted, “adding 2 workplaces was a piece of cake.”

Is maintenance complex?
Maintenance is minimal. We recommend an annual nozzle inspection and filter replacement. Our team is available 24/7 for remote support by phone, video and email.

At what outside temperature does misting become effective?

High-pressure misting works through evaporative cooling — the drier and hotter the air, the greater the effect. At typical central European summer conditions (30°C, 40–50% relative humidity), a well-designed system delivers 6–8°C of ambient temperature reduction at workstation level. In more humid conditions (above 70% RH), the effect is reduced but still measurable at 2–4°C. Our engineers size systems based on your local climate data to ensure realistic performance expectations.

Can the system run automatically without operator intervention?

Yes. Systems are typically controlled by a thermostat or hygrostat that activates the pump automatically when the temperature exceeds the set point, and switches off when the target is reached. Timer-based control (e.g. active during working hours only) is also standard. For larger facilities, zone controllers allow independent control of different areas from a central panel or building management system.

What happens to the misting system in winter?

In temperate climates, misting systems are typically inactive between October and April. The system should be drained and blown through with compressed air before the first frost to prevent damage to nozzles and pipework. This winterisation procedure takes approximately 30–60 minutes and is described in the installation manual. The pump unit is stored indoors or protected from freezing. In spring, the system is recommissioned and ready for the cooling season within a few hours.

Request a quote or ask about dealer terms: +31 85 273 3970 | info@fogsystems.eu

How the system works

Water sprayed at high pressure evaporates almost instantly in warm, dry air. That phase change — liquid to vapour — absorbs heat: one litre of water provides the equivalent of 650 watts of cooling. Unlike conventional air conditioning, there is no compressor, no refrigerant, and no ductwork. The system scales with the space: add nozzle lines as the facility grows.

For dealers and installers

We supply HVAC installers and climate control companies with the full TECNOCOOLING component range for industrial cooling projects. Pump units, stainless steel nozzles, fittings, tubing, and valves — all available with dealer pricing and technical documentation.