Case Study: Optimizing Air Quality and Efficiency with Sol-In

This case study explores how Sol-In’s advanced AI & IoT-based full management system was implemented at a metalworking plant to address challenges in indoor air quality, worker safety, and energy optimization. Using ESG principles as a framework, Sol-In provided real-time data and actionable insights, leading to significant improvements in air quality, operational efficiency, and compliance with environmental standards.

Introduction

Since its establishment, Sol-In has consistently exceeded expectations by delivering benefits beyond the original scope of its system. Designed to optimize energy use, improve air quality, and create healthier, more productive environments, the Sol-In system addresses diverse client needs while ensuring alignment with sustainability goals.

This case study aims to showcase how the system was implemented in a metalworking plant, highlighting its ability to adapt to challenges, enhance workplace safety, and significantly improve indoor air quality. By doing so, we aim to inspire property owners, building managers, and organizations to discover the environmental, health, and economic benefits of Sol-In.

To respect client confidentiality, the case study focuses on the key outcomes and operational improvements without disclosing sensitive details.

 

Defining the Problem

The production plant featured in this case study specializes in manufacturing high-precision aluminum parts, among other materials. The facility operates with existing fresh air and ventilation systems to maintain basic air circulation. However, due to the nature of metalworking, the indoor environment presents significant challenges, including emissions of fine particulate matter (PM2.5), elevated energy consumption from ventilation systems, and potential risks to employee health. To address these issues, the plant sought a reliable and data-driven solution to improve air quality while safeguarding workers and optimizing operational efficiency.

 

The Task: Ensuring Worker Safety

The primary task for Sol-In was to collect accurate data to provide a comprehensive picture of the plant’s air quality, enabling informed recommendations for improving worker’s well-being, comfort, safety and operational efficiency. This challenge was approached using the framework of ESG principles:

• Environmental: Metalworking facilities often consume high amounts of energy to operate ventilation systems while emitting pollutants into the indoor air. The task involved reducing energy consumption without compromising air quality, thereby achieving a more sustainable operation.
• Social: Worker well-being was at the core of this initiative. Employees spend long hours breathing indoor air, which, if polluted, can lead to health risks, increased sick days, and reduced productivity. Sol-In’s system provided real-time data and actionable insights to mitigate these risks, ensuring a safer and healthier workspace.
• Governance: This task required balancing environmental, economic, and health priorities to achieve regulatory compliance, such as meeting LEED certification standards, while maintaining efficient and cost-effective operations.

 

Installation Details

To address the plant’s air quality challenges, Sol-In installed three air quality monitoring systems in strategically selected areas of the facility. These included:

1. Office Area: Monitoring air quality in spaces where employees spend extended periods ensures a comfortable and healthy environment for administrative staff.
2. Lathe and Production Area: This zone was chosen for its high activity level and significant potential for air pollution due to metalworking processes.
3. Milling Area: Positioned to capture data from operations involving fine particles, a major contributor to indoor air contamination.

The placement of these systems was carefully planned to provide a comprehensive view of air quality across high-impact areas. The sensors continuously collect data, which is processed in the cloud and relayed to the plant managers in real-time. This setup allows for actionable insights and proactive decision-making to optimize ventilation and air purification.

Primary Goal: Data Collection

The initial phase of the project centered on gathering comprehensive data to understand the facility’s air quality and usage patterns. Sol-In’s sensors collected data every few seconds, focusing on key metrics such as PM2.5, CO2 and VOCs levels, temperature, humidity, and occupancy. This provided the foundation for understanding environmental conditions and identifying potential areas for improvement.

Key Measurements:

• 5 Levels: The average PM2.5 concentration was 199 µg/m³, with significant spikes noted during CNC cleaning processes, particularly after the lunch break when workers resumed their tasks.
• Ventilation Patterns: The air exchange system was programmed to run from the start of the workday until the end, aligning with work hours. However, peaks in air pollution were observed when cleaning activities overlapped with the workers’ return from breaks.
• Comfort Levels: Temperature and humidity varied across the monitored zones, highlighting areas where adjustments could enhance worker comfort.

These measurements provided the plant managers with actionable insights into their facility’s air quality and ventilation performance, setting the stage for targeted recommendations and improvements.

 

Analyzing the Data and Addressing Issues

Once the data was collected, Sol-In’s system enabled a thorough analysis to identify critical issues impacting air quality, comfort, and energy efficiency. This process provided actionable insights for targeted interventions:

Identified Issues:

• Air Pollution: High PM2.5 levels, particularly during CNC cleaning processes, posed risks to worker health and productivity.
• Ventilation Inefficiencies: Peaks in air pollution occurred due to improper timing of cleaning and ventilation activities.
• Comfort Levels: Variations in temperature and humidity indicated areas where environmental conditions could be optimized.

Solutions Implemented:

Based on the analysis, specific recommendations were implemented:

1. Adjusting the schedule of CNC cleaning to occur after working hours to allow sufficient air exchange before the next day.
2. Fine-tuning the ventilation system to operate more effectively during critical times.

These targeted actions were informed by real-time and historical data, enabling the plant to address issues systematically while improving overall efficiency and air quality.

 

Recommendations for Improvement

Based on the data analysis, several actionable recommendations were provided to the plant to improve air quality and operational efficiency. These recommendations focused on practical changes that could be implemented manually, offering flexibility for clients who are not yet ready for full automation.

Key Recommendations:

1. Optimize CNC Cleaning Schedule:

• Conduct CNC cleaning processes at the end of the workday, allowing sufficient time for the air exchange system to clear any resulting pollutants overnight.
• This adjustment aims to reduce PM2.5 spikes during active work hours.

2. Enhance Ventilation Efficiency:

• Schedule the air exchange system to activate shortly before employees arrive and continue briefly after the workday ends. This ensures optimal air quality during critical periods while reducing unnecessary energy consumption.
• Utilize the Ceiling Fan: Turn on the large ceiling fan whenever the air exchange system is running. The fan helps direct pollutants toward the air exchange system, making the cleaning process more efficient by improving air circulation.

3. Monitor and Adjust Environmental Parameters:

• Regularly review air quality data to identify any recurring issues and adjust ventilation or temperature controls accordingly.

The recommendations were implemented on September 17, 2024.

Automation and Continuous Monitoring

Automation plays a vital role in optimizing air purification, HVAC systems, and lighting for the plant. Once the data was analyzed and recommendations implemented, Sol-In’s system allowed for seamless integration of automation to enhance efficiency and maintain consistent air quality.

Key Benefits of Automation:

1. Smart System Operation:

• Air exchange and purification systems automatically adjust based on occupancy and air quality data.
• HVAC and lighting systems respond dynamically, reducing energy waste.

2. Proactive Monitoring:

• Real-time alerts notify management of any deviations in air quality or system performance.
• Predictive analytics enable preventive actions to maintain optimal conditions.

3. Sustainability and Compliance:

• Automated processes ensure adherence to air quality and energy standards while reducing operational costs.

Continuous Monitoring:

Even with automation, continuous data collection ensures the system adapts to changes in the environment or operations. This feedback loop provides ongoing insights, empowering the plant to make further refinements when needed.

Automation not only improves operational efficiency but also ensures a healthier and more sustainable work environment, aligning with the plant’s long-term goals.

 

Transform Your Building Today

Discover how Sol-In can help your facility achieve healthier indoor air quality, improved energy efficiency, and compliance with sustainability standards. Contact us now to explore tailored solutions for your building’s unique needs.