Perfect Match: Indoor Climate, Efficiency and Color WOLF Air Handling Units for a Temperature Controlled Logistics Warehouse for Pharmaceuticals
International freight forwarder Eberl, based in Nussdorf, makes no compromises when it comes to conditioning its new temperature‑controlled high‑bay warehouse and relies on WOLF ventilation technology. Since only pharmaceutical products are stored and picked in the GDP‑certified warehouse, the ventilation system was designed with full redundancy. With an air change rate of 2 × 60,000 m³/h, two WOLF KG Top AHUs operate alternately to ensure precise room temperatures and uniform humidity levels throughout the hall.
In 2023, ‘International Spedition Eberl’ responded to the growing demand for storage capacity for pharmaceuticals and invested in a state‑of‑the‑art logistics hall at its conveniently located site in Nussdorf, offering space for 25,000 pallet positions.
GDP Standard
The storage of medicinal products places significantly higher demands on logistics infrastructure than the storage of food. Fluctuating humidity and temperature can directly compromise the safety and efficacy of medicines. For this reason, the entire supply chain in Germany is strictly monitored by the Federal Institute for Drugs and Medical Devices (BfArM).
The institute prescribes proper storage to ensure that medicines remain stable and effective until the manufacturer’s stated expiration date. These requirements are essential to guarantee the efficacy and integrity of the products throughout the entire supply chain. Companies involved in the storage and transport of pharmaceuticals must therefore meet stringent standards and provide specialized infrastructure. Only then can the safety of patients be always ensured.
The new hall, covering 9,000 m² and reaching up to 13 m in height, had to be constructed as a temperature‑controlled logistics facility tailored to the demanding storage conditions. The entire logistics center was certified according to the internationally recognized GDP standard (Good Distribution Practices). This certification confirms the quality, temperature control, cleanliness, traceability and safety of the warehouse and identifies the operator as a reliable partner within the pharmaceutical supply chain.
Controlled Humidity
For the operators of the logistics hall, not only technical reliability and system redundancy were critical, but also compliance with strict climate criteria: Relative humidity must consistently remain below 75 percent, and room temperatures must always stay within the specified range of 15 to 25 °C and at every point in the hall.
Energy efficiency played an equally important role in keeping operating costs as low as possible. In addition, the climate and ventilation systems installed outdoors needed to blend aesthetically with the distinctive color concept of the building.
Managing directors Thomas and Maximilian Eberl are well aware, that the operating costs of an air handling unit can amount to around four times the initial purchase cost over its lifecycle. Since this significantly impacts overall profitability, they placed great emphasis on identifying an exceptionally energy‑efficient ventilation solution.
WOLF KG Top Air Handling Units
During their research, the performance data of the WOLF KG Top air handling units proved convincing. With state‑of‑the‑art rotary heat exchanger technology, heat recovery efficiencies of 82 percent are achieved. The latest‑generation EC fans also operate far more efficiently than conventional systems.
“Over a service life of 15 to 20 years, this results in operating cost savings of between 30 and 40 percent,” calculates Thomas Eberl. “And this also has a positive effect on the CO₂ footprint of the Eberl Group.” With its energy‑efficient design, the temperature‑controlled warehouse perfectly complements Eberl’s new fleet of electric trucks equipped with advanced thermal management technology.
The visually striking roof structure, consisting of three large, interconnected gable roofs, dictated the routing of the air ducts for plant engineering firm Robert Aigner GmbH of Fridolfing: Conditioned air is supplied through the main duct along the longitudinal side of the hall at ceiling level. Branch ducts extend from this main trunk above the racks into each aisle of the high‑bay warehouse.
Rotary Heat Exchanger
Air dampers ensure that the same volume of air is supplied to and extracted from each aisle, allowing supply air—enriched with 10 percent fresh outside air—to circulate evenly throughout the hall.
Within the AHU, the rotary heat exchanger ensures that the air does not become too dry in winter and that excessive humidity is kept outside in summer. This is possible because the leakage rate of the WOLF KG Top in this specific configuration is only around 2 percent. In the truck loading zone, vestibules ensure that indoor and outdoor air do not mix.
Temperature conditions in the rack area are continuously monitored using optimally positioned and calibrated data loggers. These are connected to a central unit that records real‑time data without interruption, ensuring immediate intervention in the event of deviations. The locations of the data loggers in the building were determined through warehouse mapping. Optimal temperature control is essential for effective inventory management, cost control and—most importantly—product safety.
Short Delivery and Installation Times
Planning, delivery and installation times for the two identical air handling units were exemplary. Because the WOLF KG Top is built using a modular system and can be produced quickly, only 30 working days passed from order placement to factory dispatch.
On site, additional time was saved because the AHUs were pre‑wired at the factory and WOLF acted as site supervisor. As a result, the two units—delivered in modules and coated in RAL 7016—were assembled and commissioned by the plant engineering company and Elektro Billinger in just 10 days under excellent weather conditions. This ensured that the facility was fully operational by July 1, 2024.
More information about WOLF ventilation technology is available at: https://www.wolf.eu/en-de/professional/ahu-products