7 Climate Control Tips to Reduce a Factory's AC Bill in the Blink of an EyeIf you set the AC thermostat at 70° to keep everyone in the factory happy, how high would you be willing to set it to save money? You could move it to 75 or 78 and save money right off the bat. But, employee complaints would increase, too.

Linking your HVAC experience with a high volume, low speed (HVLS) fan installation lets you operate your systems at 75° or more and still enjoy the 70° comfort level with the cool breeze going across you. With the advent of high-quality HVLS fans, says industry expert Jason Hornsby,

“We see that a lot of facilities engineers are getting more educated as to the value of installing air conditioning in conjunction with HVLS fans.”

Through the addition of a HVLS fan, there is less wear on the HVAC, systems can last 30% longer or more. Hornsby advises that he has a client who is an auto shop in the South. They had 2 10-ton HVAC units and were still feeling the effects of the hot and humid summers. The shop would open their doors, pull a van in and then shut them again before pulling them in for another hot car. Hornsby worked with the auto shop and installed a HVLS fan. According to Hornsby,

“With the installation of an HVLS fan the shop was able to turn off one of the 10-ton units.”

Consider These 7 Climate Control Tips to Reduce Your Factory’s AC Bill:

1. Talk to an Expert

When looking to reduce your facilities AC bill consult a specialist. They will have the tools and experience to maximize your energy savings. If you are looking to purchase a HVLS fan to supplement your cooling, look for a manufacturer who has a local distribution. Working with a local distributor helps ensure that you have someone who understands your particular climate and can work with you start to finish on the project.As Hornsby pointed out, “Someone in California is not going to understand the challenges that a facility in the South has nearly as well as a distributor who lives and works in that climate.”

2. Measure the Needs

Climate control is more about moving the air than it is about cooling the air. A horizontal fan of a large diameter moves 10-20 times the volume of air over the entire space as opposed to a vertical fan that moves air in only one direction in a much smaller volume.If you are working with a distributor you can expect that they will visit the facility with tools to determine length, width, and height of the space and take into account any air flow obstacles to match the best product.

3. Reduce the Air Conditioned

With HVLS fans, engineers can design smaller air conditioning systems for larger factory facilities. When you reduce the air conditioned by 100 tons of air, you save on equipment, installation, and energy. According to Hornsby, “If you back out 100 tons of air and have to buy 10 fans, these 10 fans are only going to run for $1 a day, whereas that air conditioner system treating that extra 100 tons is going to cost you around $5,000 a month to operate.”

4. Reverse the Flow

Some HVLS fans move a column of air the equivalent in size of a school bus. In doing so, the airflow changes the temperature stratification. Because the fan direction and speed are variable, you can manage the air movement to maximum effect in remote corners.

5. Tune Up Equipment

Inspecting all climate control equipment routinely will assure efficiency. Filters, ductwork, and thermostats all need testing on a formal schedule. Older equipment needs review for energy efficiency, and any new equipment should have Energy Star ratings.

6. Maintain the Facility

No system can manage a factory that leaks like a sieve. You need a strategic maintenance program that checks on insulation, drafts, and the building Energy Star status.

7. Reduce Operation Equipment

Machines, forklifts, conveyors, and so on all burn energy. Anything that moves, runs, or burns should be reviewed for energy efficiency, used sparingly, and kept in good repair. Anything that needs cooling reduces the efficiency of the best cooling system.The continuous air movement provided by strategically sized and placed HVLS fans has a drying effect by removing the moisture from the floor and skin surface. It reduces the need for dehumidification and air conditioning. And, it does so precisely, efficiently, comfortably, and reliably.


When looking to reduce your factories AC bill it is important to find a solution that meets your short and long term goals. Improvements need to be made that maintain employee comfort and ensure their safety. Regular maintenance of your existing HVAC along with the addition of a HVLS fan can reduce your energy consumption by over 30% while also increasing the life of your HVAC system by not pushing it as hard.

Jason Hornsby is the owner/ President of Vector Sales and the Regional Sales Rep for MacroAir Fans. An expert with high volume, low speed fans, Jason has spent more than 22 years focused on cooling solutions for industrial facilities that increase employee comfort and decrease energy consumption.

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