14 December 2023

Case Study: Air Filtration Enhancement in a Major Logistics Hub

Sector: Logistics/Warehousing

Location: Central England


The Westbury Group, responding to the needs of a rapidly growing logistics sector in the UK, undertook a project to enhance air filtration systems in a large logistics hub.

This case study details the project’s challenges, solutions, and outcomes, highlighting our innovative approach to optimising air quality and energy efficiency within a demanding operational environment.


The logistics and warehousing sector in the UK is characterised by its non-stop operation and a combination of activities that generate particulate matter.

Our client, who operate a substantial logistics hub, faced significant challenges in maintaining air quality crucial for the health and safety of staff and the efficiency of operations.

The Challenge

The client’s existing air filtration system in their Air Handling Units (AHUs) were inadequate, leading to several problems:Filter Collapse: (Pictured) Existing panel filters were collapsing due to moisture and particulate overload.

High Energy Consumption: The inefficient filtration system contributed to excessive energy use.

Space Limitations: The AHUs had limited space, hindering any substantial improvements.

Detailed Analysis and Approach:

Westbury’s team conducted a thorough assessment of the existing setup. The findings led to a multi-pronged approach:

Upgrading Pre-Filters: The collapsing filters were replaced with advanced, high-capacity pre-filters, capable of handling greater particulate loads without collapsing.

Innovative Secondary Filtration: A slimline, high-capacity secondary filter was introduced, (Pictured) fitting into the constrained space while significantly improving air quality. This as significant as another manufacturer had told the client this would not be possible. This fact underlines Westbury’s commitment to achieveing what others can or will not.

Improved Mounting Arrangements: The installation of adapted clips facilitates easier maintenance and filter replacement, reducing downtime.

Protective Air Intake Screens: These screens add an extra layer of protection, extending the life of other filters and enhancing overall air quality. Their design allows for easy removal and cleaning.

Implementation Process

Pre-Implementation: The facility struggled with failing panel filters and unprotected air intakes, leading to reduced air quality and a high maintenance requirement.

Post-Implementation: Enhanced panel and secondary filters were installed, using existing frames but with intakes, offering additional filtration and prolonging filter life.

Results and Impact

The implementation led to multiple benefits:

Improved Air Quality: The additional filtration stages significantly improve air quality within the facility.

Reduced Energy: The higher-capacity pre-filters result in lower energy consumption, aligning with sustainability goals.

Ease of Maintenance: The redesign of the mounting system simplifies the process of changing filters, reducing labour and downtime.

Cost-Effective: Using the existing mounting frames avoids the need for expensive AHU modifications.

Following the initial success, the solution was replicated across six more AHUs, leading to a plant-wide improvement in air quality and energy efficiency.

Long-Term Benefits

The project’s success is expected to yield long-term benefits:

Sustained Air Quality Improvements: Enhanced filtration ensures a healthier environment for personnel and better preservation of goods.

Ongoing Energy Savings: The efficient system contributes to reduced operational costs and aligns with environmental sustainability initiatives.

Reduced Maintenance: The ease of filter replacement and the durability of the new system reduce the burden on maintenance teams.

In Conclusion

This example of The Westbury Group’s innovative air filtration project represents a benchmark in environmental and operational excellence. Through a comprehensive approach addressing the challenges of filter collapse, high energy consumption, and space limitations, we not only improved working conditions but also set a precedent for sustainable operations in similar facilities.

Key to this success was the strategic replacement and upgrading of existing filtration systems and the introduction of high-capacity pre-filters, innovative secondary filtration, and protective air intake screens. These enhancements not only improved the hub’s air quality but also streamlined maintenance processes, reducing energy consumption. The use of existing infrastructure mitigated additional costs.       

The project’s success extends beyond immediate improvements in air quality and energy efficiency. It demonstrates a proactive approach to employee health and safety, and a commitment to environmental sustainability, aligning with broader global initiatives.

The replication of this solution across additional AHUs within the facility shows both scalability and adaptability, setting a model for other logistics hubs facing similar challenges.

This project is a testament to how innovative engineering solutions can simultaneously address environmental concerns, operational efficiency, and employee well-being across the sector.

Reach out to Westbury today to discover how your staff can enjoy the benefits of even cleaner air.

Related News

Get in touch today

For more information or to request a quote, please contact our friendly team of experts today.