8 Ways to Cool a Warehouse (Without AC)

Warehouses fulfill a critical role in the modern economy and are therefore some of our most important infrastructure. The covid-19 pandemic showed weaknesses in the supply chain, a hole that can be readily filled by more and better warehousing.

The usefulness of warehouses has to do with their being massive, able to store a substantial amount of product. The downside of their immense size is they are challenging to cool. There do exist air conditioning systems that could provide the necessary cooling to warehouses, but the costs for such systems and their associated ductwork plus the energy costs to run them is extreme, so much so that it simply doesn’t make financial sense in the vast majority of scenarios.

That said, cooling a warehouse, especially in regions where springs and summers are hot, is imperative. 

In this article, we’ll explore a variety of options that can provide significant cooling at much lower costs than air conditioning systems.

Why Warehouses Need Cooling

As noted, warehouses are important to the modern economy and its growth and need to operate efficiently without issue. During warm and hot spring and summer months, interior temperatures in warehouses without cooling can become untenable. This can cause a number of significant issues that impede on their ability to function as desired.

Protect Expensive Equipment and Housed Products

One of the main uses of warehouses is to store finished products, traditionally known as “wares,” thus the name warehouse. While modern products are packed better than they have ever been, they are still at risk of degradation or even ruination by extreme temperatures and volatile changes in humidity levels. Cooling a warehouse is therefore a prime directive, as endangering stored products defeats their entire purpose.

Additionally, warehouses require equipment to function, some more than others. Just like products, equipment subjected to extreme temperatures and humidity fluctuations can cause them to wear out faster than otherwise. The more equipment that requires maintenance and/or replacement, the more costs. Providing cooling will help equipment last longer than it would otherwise.

Workforce Well-Being

The third major component of warehouses is the workforce that runs them. Extreme temperatures create an uncomfortable work environment, which creates a number of negative consequences. For one, it decreases efficiency, as uncomfortable workers are less inclined to perform at their best. Extreme temperatures could also impact employment, as some might decide they’ll find other work, meaning management has to find new employees and get them trained - more costs.

By providing cooling to a warehouse, you can provide a comfortable atmosphere where workers are happy to be and can perform at their best.

The Problem with Air Conditioning and Warehouses

It certainly isn’t impossible to utilize air conditioning in a warehouse. The “problem” is it is almost always prohibitively expensive. Because warehouses are some of the largest structures we build, not only square footage-wise but with extremely tall ceilings, the type of air conditioning system to cool this is extreme. Not only does such a system cost a lot of money - both for the mechanical and electrical components as well as installing all of the ductwork - the costs to run the system daily could be astronomical, especially in regions with warm springs and boiling summers - the regions where you need air conditioning the most.

The good news is there are a plethora of techniques to provide cooling without air conditioning, and many are extremely cost effective.

8 Ways to Cool a Warehouse Without Air Conditioning

1. HVLS Fans

Fans are a powerful alternative to air conditioning in a warehouse because they utilize the evaporative cooling effect, a process by which air flow cools the body by evaporation of sweat. High volume, low speed (HVLS) fans are the ideal solution for warehouses because of how much air they can move with their extremely large blade widths. Because of those blade widths, they are able to move a significant amount of air while at low speeds, meaning their motors aren’t overly taxed and the costs to run them are small. Even just one or two HVLS fans can provide significant cooling to the average warehouse. 

Additionally, HVLS fans help significantly with air circulation, helping to destratify air in structures with tall ceilings. They can even be used in winter to help bring warm air that has risen above the floor back down, providing a measure of heating. 

HVLS fans from industry-leading Hunter Industrial and Big Azz Fans are the most effective and battle-tested HVLS fans in use in warehouses today.

2. Box Fans

Box fans are similar to directional fans in that they provide more targeted cooling than HVLS fans. The advantage to box fans is they typically provide more air flow (and thus cooling) than directional fans, and can be positioned at will. This of course takes up a small bit of space, but is a useful feature for more dynamic warehouse environments that have shifting cooling needs.

3. Directional Fans

Like HVLS fans, directional fans provide cooling via the evaporative effect. These fans are smaller and directional, meaning they are utilized for cooling only where needed in specific areas. Depending on your warehouse circumstances, cooling may only be needed in specific areas, meaning HVLS fans might be overkill. Directional fans are perfect for these scenarios as they can be quickly installed to target specific areas at low operational costs. They also have the advantage of being readily mounted on walls so they are out of the way and don’t take up any valuable floor space.

4. Airflow Optimization

Related to the above, it’s imperative that airflow is optimized to get the most out of any cooling system or strategy. Figuring out if there are heat pockets and where air becomes stale can inform the placement of fans and/or whether to employ an ATU, significantly optimizing their capability at providing cooling.

5. Air Turnover Units (ATUs)

Air turnover units (ATUs) are systems that provide high-volume air recirculation to help provide cooling and dehumidification in large open spaces. Essentially, they perform more enhanced and efficient air circulation than fans alone, and therefore can be a powerful tool in situations where internal temperatures are in need of more cooling than that which fans, even HVLS fans, can provide. ATUs, in conjunction with an array fans, are a fantastic option for the highest of cooling needs without having to break the bank for expensive, energy-intensive air conditioning systems.

6. Exhaust Fans

Exhaust fans are a powerful tool to exhaust hot air from within warehouses to the exterior. For situations where temperatures aren’t overly extreme, exhaust fans can provide cooling by extracting warm air from within and providing cooler air from without. During periods of hot weather during the day, air inside structures can stay warmer than the air outside once temperatures fall later in the day. By providing an exchange of air, exhaust fans can make sure the interior climate of a warehouse is as cool as it can be.

For situations where cooling is a significant priority due to extreme temperatures, exhaust fans can significantly complement HVLS, directional, and/or box fans by providing necessary air exchange with the external environment.

7. Evaporative Cooling Systems

Evaporative cooling systems, also known as swamp coolers, provide cooling by evaporating water into the air, which absorbs the air's heat and therefore provides cooling. These systems are typically more cost-effective and less energy-intensive than ATUs, but are less powerful, meaning they are best suited for small to mid-sized warehouses. It’s also why they are commonly found in residential applications, due to their ability to be effective in small spaces.

Evaporative cooling systems work best in arid, low humidity environments as they work on the principle of humidity, and are thus less effective in humid environments. In combination with one or two HVLS fans, they are a great option depending on the climate and size of the warehouse.

8. Shade Structures

Helping to limit the penetration of external temperatures from entering the warehouse in the first place is a great strategy to limit the need for interior cooling. One effective way to do this is to provide shade structures like awnings, overhangs, or shade screens to key exterior sections of the warehouse.

For the Best in Industrial Fans for Warehouse Cooling, Work with TBC Supply

The most powerful cooling option in the absence of air conditioning is to rely on industrial-grade HVLS, directional, and/or box fans. The evaporative cooling effect provides serious cooling and even just a few HVLS fans could make a world of difference.