Energy efficient heating and ventilation of a factory hall by monitoring the indoor air climate

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Accordingly, it often makes sense to analyze the actual operating conditions again during subsequent operations in order to optimally adapt the air supply to the respective conditions in terms of demand-responsive ventilation. The aim is to ensure good indoor air quality and thermal comfort while significantly reducing energy consumption. Methods For this purpose, in addition to the sensors in the building management system, approximately 120 wireless sensors were installed in the occupied areas to measure the air temperature, operating temperature, humidity, and CO2. In this way the spatial and temporal distributions of temperature, humidity, and CO2 in the hall were visualized and evaluated to reduce the volume flows of the ventilation systems. The recorded data and findings were used to optimize ventilation systems by gaining a deeper understanding of indoor air flow. Results As part of the investigation, a considerable reduction in the air volume flows and thus the required energy consumption of the air handling units was achieved while maintaining the same thermal comfort. It was shown that the temperature field and indoor air quality were not negatively affected by the change in the air volume flow over a wide range. Conclusions This was made possible by the well-designed ventilation system, which achieves a low-pulse, slightly stratified indoor airflow, and a structural envelope with very good thermal insulation. 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F1000Research 2024, 13 :1309 ( https://doi.org/10.12688/f1000research.153972.1 ) NOTE: If applicable, it is important to ensure the information in square brackets after the title is included in all citations of this article. Close Copy Citation Details Export Export Citation Sciwheel EndNote Ref. Manager Bibtex ProCite Sente EXPORT Select a format first Track Share ▬ ✚ Research Article Energy efficient heating and ventilation of a factory hall by monitoring the indoor air climate [version 1; peer review: 1 not approved] Yose Wandy 1 , Ralf Gritzki 1 , Markus Rösler https://orcid.org/0009-0005-2527-9049 1 , Alf Perschk 1 , Clemens Felsmann 1 Yose Wandy 1 , Ralf Gritzki 1 , [...] Markus Rösler https://orcid.org/0009-0005-2527-9049 1 , Alf Perschk 1 , Clemens Felsmann 1 PUBLISHED 31 Oct 2024 Author details Author details 1 Chair of Building Energy Systems and Heat Supply, Institute of Power Engineering, Technische Universität Dresden, Dresden, Saxony, Germany Yose Wandy Roles: Conceptualization, Data Curation, Formal Analysis, Visualization, Writing – Original Draft Preparation Ralf Gritzki Roles: Conceptualization, Formal Analysis, Software, Visualization, Writing – Original Draft Preparation Markus Rösler Roles: Methodology, Validation, Writing – Original Draft Preparation Alf Perschk Roles: Conceptualization, Data Curation, Software, Visualization Clemens Felsmann Roles: Methodology, Supervision, Validation, Writing – Review & Editing OPEN PEER REVIEW DETAILS REVIEWER STATUS Abstract Background Different usage scenarios and design guidelines were considered when planning a factory building and its ventilation system. Accordingly, it often makes sense to analyze the actual operating conditions again during subsequent operations in order to optimally adapt the air supply to the respective conditions in terms of demand-responsive ventilation. The aim is to ensure good indoor air quality and thermal comfort while significantly reducing energy consumption. Methods For this purpose, in addition to the sensors in the building management system, approximately 120 wireless sensors were installed in the occupied areas to measure the air temperature, operating temperature, humidity, and CO2. In this way the spatial and temporal distributions of temperature, humidity, and CO2 in the hall were visualized and evaluated to reduce the volume flows of the ventilation systems. The recorded data and findings were used to optimize ventilation systems by gaining a deeper understanding of indoor air flow. Results As part of the investigation, a considerable reduction in the air volume flows and thus the required energy consumption of the air handling units was achieved while maintaining the same thermal comfort. It was shown that the temperature field and indoor air quality were not negatively affected by the change in the air volume flow over a wide range. Conclusions This was made possible by the well-designed ventilation system, which achieves a low-pulse, slightly stratified indoor airflow, and a structural envelope with very good thermal insulation. READ ALL READ LESS Keywords Indoor air climate, Factory hall, Energy consumption, Ventilation, Sensors Corresponding Author(s) Markus Rösler ( [email protected] ) Close Corresponding author: Markus Rösler Competing interests: No competing interests were disclosed. Grant information: The Article Processing Charge (APC) were funded by the joint publication funds of the TU Dresden, including Carl Gustav Carus Faculty of Medicine, and the SLUB Dresden as well as the Open Access Publication Funding of the DFG. The funders had no role in study design, data collection and analysis, decision to publish, or preparation of the manuscript. Copyright: © 2024 Wandy Y et al . This is an open access article distributed under the terms of the Creative Commons Attribution License , which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited. How to cite: Wandy Y, Gritzki R, Rösler M et al. Energy efficient heating and ventilation of a factory hall by monitoring the indoor air climate [version 1; peer review: 1 not approved] . F1000Research 2024, 13 :1309 ( https://doi.org/10.12688/f1000research.153972.1 ) First published: 31 Oct 2024, 13 :1309 ( https://doi.org/10.12688/f1000research.153972.1 ) Latest published: 29 Apr 2026, 13 :1309 ( https://doi.org/10.12688/f1000research.153972.2 )  There is a newer version of this article available. Suppress this message for one day. Highlights • This study shows that it is possible to optimize the ventilation systems in a factory hall with a network of commercially available sensors for indoor climate and operate them economically. • The spatial and temporal distributions of temperature, humidity, and CO 2 in the hall were visualized and evaluated to reduce the volume flows of the ventilation systems. • The recorded data and findings were used to optimize ventilation systems by gaining a deeper understanding of indoor air flow. • It was shown that the temperature field and indoor air quality were not negatively affected by the change in the air volume flow over a wide range. 1. Introduction This study uses the automotive industry as an example to discuss the possibilities for energy savings through demand-responsive ventilation. Automobile production can be roughly classified into press shops (production of body parts), body shops (welding and assembly of body parts), paint shops (painting body parts), and assembly shops. Figure 1 shows the classification of energy consumption according to the production areas of the automobile industry. The assembly line is responsible for almost a quarter of the total energy consumption, preceded by paint and body shops. HVAC systems are responsible for more than 65 % of the total energy consumption in the assembly, succeeding in other infrastructure systems, halls, and workplace lighting ( Volkswagen AG, 2023 ). Figure 1. Energy consumptions broken down by production areas ( Volkswagen AG, 2023 ). On par with the paint shop, the assembly line also accounts for the highest energy consumption of HVAC systems. Almost one-third of the HVAC consumption in automobile manufacturing can be located in the assembly line. The main reason for this is that there are more workers in an assembly hall than in other manufacturing areas. In terms of occupant thermal comfort demand, Figure 2 shows that HVAC heating and electricity consumption resulting from space heating and electric drives in HVAC systems responding to the thermal comfort demand of approximately 36 % in total is higher than process-related HVAC consumption, that is, occupant comfort is more demanding than process-related HVAC energy consumption ( Volkswagen AG, 2023 , based on several locations). Figure 2. Breakdown of thermal and electrical energy consumption in an automobile manufacturing ( Volkswagen AG, 2023 ). HVAC systems in factory halls are often generously dimensioned to ensure greater flexibility in hall utilization. Accordingly, it is important to develop and use efficient control systems to optimize HVAC control for current hall use. The aim is to find a compromise between the lowest possible energy consumption and the best possible thermal comfort. This is made possible by optimizing the required air volume flow based on a detailed assessment of the resulting air distribution. The challenge when ventilating large rooms such as a factory hall is the ratio of a very large and high room to a small occupied zone (see Heiselberg et al.,1998 ). The ventilation system should be designed such that fresh air is always supplied to the occupied zone. The remaining room volume was of secondary importance. Additionally, vertical temperature gradients with higher temperatures in the upper hall area should be avoided to prevent energy loss. In other words, stratification in terms of indoor air quality is helpful; however, stratification in terms of temperature should not occur. If such a comfortable condition is achieved at a certain ventilation level, for example, through diffusers close to the floor, it should be maintained with every optimization. Ensuring this is difficult because of the complex interplay between the different types of ventilation and thermal loads in indoor air flow. Accordingly, the aim of the studies presented here is to identify ways to reduce electrical and thermal energy consumption while ensuring thermal comfort and indoor air quality. This was achieved by monitoring the climatic conditions in several representative areas of the hall in great detail, both spatially and temporally. Various operating parameters for the HVAC control system were varied, the effects of these variations on the indoor climate were measured, and the achievable energy-saving effects and effects on indoor air quality were determined. This paper presents the corresponding results for both summer and winter cases and analyzes them in terms of potential energy savings. 2. Methods 2.1 Description of the measurement site This article describes an experiment and field test conducted to improve the energy efficiency and effectiveness of an HVAC system of a factory building in the automotive industry in Września, Poland, using indoor air quality parameters. The factory building was built in 2014 and is divided into two sections. The northern section ( Figure 3 , right) of the hall is the main assembly line area (Montage); it stretches over 475 m in length, whereas the southern section of the hall, which has a length of 375 m, is reserved for the finishing area ( Figure 3 , left). In the finishing area the manufactured cars are processed, washed and inspected thoroughly before the final test drive, this area of the hall is significantly narrower than the assembly line area. Figure 3. Floor plan of the investigated factory building and distribution of the ventilation zones. The assembly area (Montage; M01 to M16) is served by 16 HVAC systems, whereas the finishing area is served by six HVAC systems (F01 to F06). However, with regard to the production process, the HVAC in the finish area is not only used to condition the building area, but also to supply quality control and test drive, for example, roller test rig. This limits the design of the experiment; only the main assembly line area (M01–M16) can be used for experiments with. The 16 HVAC supply systems installed in the assembly hall are presented in Table 1 . The HVAC systems in the finish line were outside the scope of this study, and remained unchanged throughout the experiment. Each of the 16 HVAC systems was equipped with two ventilator resps. fans on the supply side, and two fans on the exhaust side. The supply air fans of M01-M04 have a nominal electric power of 18.5 kW, while all other fans have a power of 22 kW. Exhaust air fans operate at nominal power of 18.5 kW, 22 kW resp. 30 kW, depending on the system. They can deliver air flow rates of up to 63,000 m 3 /h or 75,000 m 3 /h at the nominal power. In total, 64 fans in the assembly area required 676 kW of fan power on the supply air side and 740 kW of fan power on the exhaust air side. Table 1. List of installed HVAC systems in the assembly area and the nominal data (parameters per system). HVAC number Supply air volumetric flow rate of each HVAC [m 3 /h] Electrical power of the supply fans [kW] Exhaust air volumetric flow rate [m 3 /h] Nominal electrical power of the exhaust fans [kW] M01 – M04 63,000 2 x 18.5 63,000 2 x 18.5 M05 – M12 75,000 2 x 22.0 75,000 2 x 22.0 M13 – M16 75,000 2 x 22.0 75,000 2 x 30.0 The floor area and nominal supply air volume flow rates of dedicated HVAC systems for the complete hall are summarized in Table 2 . Table 2. Selected building and HVAC design parameters of the hall. Area Floor area [m 2 ] Supply air volume flow [m 3 /h] Area specific flow rate [m 3 /hm 2 ] Finish 18,125 411,500 22.70 Montage 73,438 1,152,000 15.69 Hall 4 91,562 1,563,500 17.08 Based on data given, the floor related supply air volume flow rate of the HVAC system for the assembly area for this case study is calculated at 15.69 m 3 /hm 2 . However, owing to the narrow construction of the building and higher demands on air quality as a result of the exhaust gases released, the finishing area has a much higher specific volumetric flow rate than the assembly line area. In view of the very high air quality recorded in the hall so far, the question arises as to whether it’s necessary to deliver volumetric flow rates of air of up to 22.70 m 3 /hm 2 . These are the design state conditions with typical flow rates for assembling halls between 20 m 3 /hm 2 and 30 m 3 /hm 2 ( VDI 3802, 2014 ). A reduction in the volume flow rate leads to a significant reduction in the fan electric power consumption for air transport and distribution. The operation of fans is governed by a consistent set of laws dictated by speed, power, and pressure. If the speed (RPM) of a fan is altered, it will reliably result in a corresponding change in the power required to run it at the new RPM, as well as the pressure rise it generates. The volumetric flow rate of the fans was calculated based on the relationship between the flow power of the fan and its speed ( VDI 6014, 2016 ). N 1 N 2 = V ̇ 1 V ̇ 2 and P 1 P 2 = ( N 1 N 2 ) 3 where: P 1 , P 2 = Flow Power in [ W ], V ̇ 1 , V ̇ 2 = Volumetric Flow Rate [ m 3 h ] N 2 , N 2 = Fan Speed [RPM]. Speed control by frequency control flow power is not very different from the electrical power of the fan; therefore, these relations are often used to estimate electrical power consumption in a very simplified way ( Bureau of Energy Efficiency, 2023 ) and can be treated in the same way here or by ( VDI 6014, 2016 ). Because the air flow is proportional to the speed of the fan, slowing down the fan also means a linear reduction in the volumetric flow rate, so that a 10 % reduction in volumetric flow rate will lower the electrical power demand by approximately 30%. The HVAC systems listed in Table 1 are shown on the right side of Figure 3 , which shows the outline of the supply air ventilation zone according to the distribution of the supply air duct system in the hall. The heating demand of the building was covered by using direct gas heaters and heat recovery in the HVAC system. They do not have humidifying, dehumidifying, or cooling capabilities. Air is supplied close to the occupied zone and workplaces by displacement, such as diffusers (for low momentum stratified flow) at a height of approximately 3 m. In this way, the ventilation system generates a uniform velocity and temperature field in the complete hall. During the heating period, the HVAC system was set to establish a 20.5 °C of room air temperature under all conditions in this study, measured at two different positions at approximately 3 m height for each system. Figure 4 shows a schematic of the parts used in the HVAC system installed in the factory hall, which applies to each of the 16 HVAC systems. Figure 4. Schematic representation of the HVAC system (ventilator means here a couple of fans). 2.2 Data sampling and analysis As mentioned above, each ventilation system was equipped with temperature and CO 2 sensors close to the East and West walls of the building at a height of approximately 3 m. This is very helpful, but not enough, to monitor thermal comfort and indoor air quality close to the workplace. Therefore, a network of approximately 120 sensors for air temperature and humidity, and some additional sensors for operative temperature and CO 2 were installed. However, this was not sufficient to obtain the details of the indoor air climate of the complete hall. Thus, four zones were recognized as representative based on the production process, and worker occupancy was defined in the hall. The locations of these zones are shown in Figure 5 . Of these zones, Zone 4 was selected for the reduction of the air flow rates and for this study. In this area, there are several windshield gluing machines and workers performing manual work, as well as a break area for workers. Zone 4 was supplied by the ventilation systems M05–M08. Figure 5. Zones for the indoor climate monitoring shown in the factory layout. Figure 6 shows an overview of the installations used to measure temperature, relative humidity, and CO 2 in zone 4 as an example. The setup consists of a vertical air temperature and humidity profile within the reach of the server transmitter area with nine–ten sensors. The reason for this is to measure the temperature gradient from floor to ceiling, so that we can ensure that there are no large temperature differences that could cause unpleasant draughts. The vertical distance between the sensors was 1 m, and the uppermost sensor was fixed to the bottom of the roof frame. In addition, there were two to three “smaller” vertical temperature profiles with four to five sensors spaced 2 m apart. Operative temperature and CO 2 sensors were installed at a height of approximately 1.50-1.60 m, close to the worker’s area. Figure 6. Locations of the installed sensor nodes in zone 4. Figure 7 shows the detailed positions of the sensors in relation to the relevant nearby facilities, such as the break room, windscreen bonding system, manipulators, and screws. Sensor S 1 was placed in proximity to the air supply duct of the HVAC system. Five Sensors were installed on S 4 at regular distances starting from 1.5 m height to 3 m, 5 m, 7 m, and 9 m, respectively, to monitor the room temperature at the working level and to monitor the vertical temperature gradient in the hall. In Figure 8 , examples of the installed routers, gateways, and sensors used in this study are shown in Figure 8 . Figure 7. Position of the sensors of the monitoring systems. Figure 8. Installed sensors, routers and gateways on the site. The developed system was built following the approach by the authors ( Arendt et al., 2018 ), and in-depth knowledge of the structure and structural elements of the building was not required. The approach to hardware development was expandable and exchangeable with other possibilities of data inclusion. The sensors used to measure temperature and humidity are from Technoline (TX29 DTH-IT) and are capable of transmitting the measured data at a frequency of 868 MHz. All sensors were calibrated accordingly prior to use, and the error tolerances were approximately +-0.3 K and +-5 %, respectively. To upload the measured data to the web servers of TU Dresden, the appropriate receiver (JeeLink) must be configured on a Raspberry Pi (RPi) server. Each RPi Server has a coverage of 50 m –100 m and can manage 30 air temperature/humidity sensors, as well as two to three operative temperature sensors and one CO 2 sensor. The respective FHEM OpenSource-based server for data management also operates on this server. The wireless sensors collect data and send them through RPi servers and a gateway to the database server at TU Dresden. The data are visualized to observe the experiments online and, if necessary, to immediately react to overshooting. Figure 9 shows the design of the communication structure of the measurement system. Figure 9. Components and connection options in the (indoor climate) measurement system. The sensor nodes remained in operation in 2019 and 2020. The analysis presented here focused on the dataset from the winter months of both 2019 and 2020. Three conditions were chosen from the dataset: March 2019 (Condition 1 or C1), April/May 2019 (Condition 2 or C2), and February/March 2020 (Condition 3 or C3). For convenience, the three conditions are mostly referred to as C1, C2, and C3, respectively. The outside temperature was between -5 °C and 20 °C in March 2019 and between -3 °C and 28 °C in April 2019. In the winter period from February to March 2020, the outdoor temperature was between -17 °C and 20 °C ( Weather Spark, 2019 , 2022 ). The three time slots are shown in Figure 10 . Figure 10. Supply air ventilation data sample from March of 2019 until the end of 2020. The objective is to investigate the potential for energy savings for the HVAC system owing to volume flow reduction while maintaining acceptable air quality and thermal comfort levels. This is achieved by varying the airflow rates (C1, C2, and C3) and observing how these changes impact the indoor climate by conducting measurements. The method of varying the air flow rates may not be systematic, but some special conditions stopped the systematic investigations in autumn 2019, especially in 2020. Therefore, we switched back to higher airflow rates after a stepwise reduction in the spring of 2019. Nevertheless, there were sufficient data for analysis. Table 3 provides information on the test conditions conducted in accordance with the time of year, power requirement, and volumetric flow rate. The “Nominal Condition” column shows the standard power requirement and volumetric flow rate of 22 kW and 2 × 37,500 m 3 /h respectively. Condition C1 (from 1st March–31st March 2019) had a lower calculated power requirement of 12 kW at a volumetric flow rate of 2 × 31,000 m 3 /h. This was the starting point of our investigation because the operator became aware of the data of the building management system that it is not necessary to run the HVAC system at maximum capacity. Condition C2 (from 18th April to 18th May2019) had the lowest calculated power requirement of 3.5 kW at a volumetric flow rate of 2 × 20,000 m 3 /h. Table 3. Test conditions in accordance to time of the year, power requirement and volumetric flow rate. Condition number Date/Time Power requirement per air fan, supply in kW Power requirement per air fan, exhaust in kW Volumetric flow rate in m 3 /h “Nominal Condition” - 22.0 22.0 2 x 37,500 C1 1st March to 31st March 2019 12.0 7.0 2 x 31,000 C2 18th April to 18th May 2019 3.5 2.5 2 x 20,000 C3 20th February to 20th March 2020 8.5 5.5 2 x 27,000 Similarly, condition C3 (from 20th February to 20th March 2020) had a calculated power requirement of 8.5 kW at a volumetric flow rate of 2 × 27,000 m 3 /h. On condition 3 (C3), the fans were reduced to approximately 8.5 kW or 40% of the electrical power and on condition 2 (C2) to about 3.5 kW or about 13.75% of the nominal power. The power requirements data were calculated using VDI 6014 (2016) and compared to the data delivered by the building management system. In the case of the supply system, the data coincide well, but for the exhaust side, the power requirement is always lower because the short-duct system generates lower pressure losses than the supply system. It should also be noted that further reductions can be achieved by further reducing the air flow rate or by switching off the ventilation at night or when there is no human presence, thus leading to further energy savings. Systems for monitoring emissions, temperature, and relative humidity are recommended so that the HVAC system can be controlled to achieve the defined thresholds. 3. Results & Discussion At the nominal point, each of the two supply and two exhaust air fans per HVAC system for the area requires 22 kW of electrical power and delivers up to 37.500 m 3 /h of supply and exhaust air, respectively. During the start of the experiment in winter 2019 (C1), the HVAC system was running at a partial load compared to its nominal capacity, and the fans were operating at approximately 12 kW or 55% of the nominal electrical power. Even under these conditions, the effect of the existing energy-saving measures is noticeable. Figure 11 shows the electrical power consumption profile of the two supply air (supply 1 and 2) and the two exhaust air (exhaust 1 and 2) fans. The fans are switched off on weekends (no production) using timer controls, which accounts for the intermittent absence of energy consumption in the graphs. Figure 11. Required electrical power for the two supply air and two exhaust air fans. 3.1 Temperature and relative humidity data Figure 12 shows the air temperature directly in front of an HVAC supply air outlet ( Figure 7 , S 1 ), whereas Figure 13 shows the room air temperature in the nearby working area ( Figure 7 and S 4 ). The mean difference between C1 and C3 was approximately 1 K when comparing the room air temperature values under all three conditions. The air temperatures during C1 and C3 also followed the weekday–weekend heating profile of the production site. C2 showed higher room temperatures in general, owing to the higher outdoor air temperature between April and May 2019 compared to February and March. In contrast to the supply air temperature at C1 and C3, the supply air temperature of C2 approximately represents the outdoor air temperature because the heating module was shut off during the warmer season transition time (April to May). This can also be observed in Figure 13 , where the room air temperature moves above the desired 20.5 °C threshold and does not follow the weekday-weekend heating profile. Figure 12. Measured supply air temperature during the three test conditions in °C. Figure 13. Measured room air temperature during the three test conditions in °C. Figure 14 (a) , (b) , and (c) show the vertical temperature profiles in the hall for all three test conditions. The temperature at 1,5 m height is often higher than that at 3 m because the supply openings are at 3 m. Figure 14. Vertical temperature difference from 1,5 to 9 m of the test conditions (a) (b) (c). Because of internal heat gains, the supply air temperature is often lower than the room air temperature. The temperature is highest at 7 m. At 9 m, the temperature drops again because the sensor is directly below the ceiling and close to or almost adjacent to the cold outside air. This vertical temperature difference can be clearly observed in Figure 14 (a) and Figure 14 (b) . During the seasonal transition C2, as shown in Figure 14 (c) , the measured air temperatures were closer to each other along the height. Overall, there is no difference in the thermal and air flow situation in the hall when comparing conditions C1, C2, and C3. This means that the indoor airflow and thermal stratification seem to be independent of the airflow rate within the range between C1 and C2. The already good situation in the indoor climate of the hall is not affected by reducing the air volume rates within the limits discussed above. For a comprehensive assessment, humidity and CO 2 levels should be evaluated in the same manner. The relative humidity measurement data for all three conditions ( Figure 15 (a) , (b) , and (c) ) show little to no differences along the height. Figure 15. Vertical relative humidity data of the three test conditions (a) (b) (c). 3.2 CO 2 Data Figure 16 shows the CO 2 measurement data for all the three test conditions. In general, the measured CO 2 concentration was in the 400–700 ppm band. The CO 2 concentrations during the C1 and C3 test periods were higher than the CO 2 concentration measured during the C2 test period. The higher concentration can be explained by the use of direct gas heating in the HVAC system during the test periods C1 and C3, which represent the 2019 and 2020 heating periods, respectively. In both cases, the difference was quite small, indicating that the CO 2 concentration was well below the Pettenkofer limit of 1,000 ppm. This knowledge is relevant for worker safety because it shows that the direct gas heater does not cause any significant increase in CO 2 emissions. Overall, this also highlights that the change or reduction in the flow rate under the chosen conditions does not negatively affect the air conditions, as can also be seen from the temperature and relative humidity results. According to the trends in globally averaged CO 2 determined from NOAA Global Monitoring Laboratory measurements, the average CO 2 concentration of outdoor air between 2019 and 2020 lies between 409 ppm and 411 ppm ( Lan et al., 2023 ). Figure 16. CO 2 measurement data of the three test conditions. 3.3 Energy savings Finally, Table 4 displays the volumetric flow rate and the measured energy consumption of the three different conditions (C1, C2, and C3) during field testing. The first column lists the condition numbers, and the second column indicates the date and time for each condition. The third column shows the volumetric flow rate in cubic meters per hour (m 3 /h) under each condition. The fourth and fifth columns indicate the energy consumption in kilowatts (kWh) for the supply and exhaust fans, respectively. Energy consumption was calculated using the data delivered by the building management system for the selected time period. Table 4. Overview of the volumetric flow rates and energy consumption of the three conditions. Condition number Date/Time Volumetric flow rate in m 3 /h Energy consumption in kWh, supply Energy consumption in kWh, exhaust C1 1st March – 31st March 2019 2 x 31,000 10,132 6,019 C2 18th April - 18th May 2019 2 x 20,000 2,798 1,742 C3 20th February - 20th March 2020 2 x 27,000 9,351 5,614 Overall, this table provides an overview of the volumetric flow rates and electrical energy consumption under the three conditions in this study. We only discuss electrical energy, although there are also savings in gas consumption, which is a subject for another publication. It is clear that energy consumption varies significantly among the three conditions. Condition C1 had a volumetric flow rate of 2 × 31,000 m 3 /h, resulting in the highest energy consumption of 16,151 kWh (10,132 kWh for supply fans and 6,019 kWh for exhaust fans). In contrast, condition C3, with a volumetric flow rate of 2 × 27,000 m 3 /h, consumed 14,965 kWh (9,351 kWh for the outlet fans and 5,614 kWh for the exhaust fans). Finally, condition C2 had the lowest energy consumption of 4,540 kWh (2,798 kWh for the supply fans and 1,742 kWh for the exhaust fans), with a volumetric flow rate of 2 × 20,000 m 3 /h. Comparing the energy consumption between the three conditions, it is clear that condition C3 had lower energy consumption than condition C1, with a significant energy saving of 1,186 kWh compared to condition C1. Furthermore, condition C2, which had the lowest volumetric flow rate compared to the other two conditions, resulted in a noteworthy reduction in the energy consumption of 11,611 kWh when compared to the energy consumed in condition C1. Overall, significant energy savings can be achieved by optimizing the volumetric flow rate and operating conditions, taking into account the current processes, and by running a network of monitoring sensors, as demonstrated by the lower energy consumption in conditions C2 and C3 compared to condition C1. 4. Conclusion In this study, we have demonstrated a method of using wireless air temperature, humidity, and CO 2 sensors in an automotive factory to gain information about local room air conditions. This information is used to improve the energy performance of HVAC systems. Approximately 120 sensors were installed at different locations and showed the data results within three test conditions, C1 with 62,000 m 3 /h, C2 with 40,000 m 3 /h, and C3 with 54,000 m 3 /h of supply air per ventilation system. During the heating period, the HVAC systems were set to maintain a room temperature of 20.5 °C. When comparing the room air temperature values for all three test conditions, the difference between the two winter use cases (C1 and C3) was minimal. During transitional period C2, the room temperatures were higher than those of C1 and C3. This was caused by the warmer outdoor air temperature between April and May 2019 compared to the months of February and March of C1 and C3. The vertical temperature sensor values in the hall for all three test conditions were also discussed. The measurements showed a uniform temperature distribution over the height (less than 1 K spread). This is an indicator of the excellent effect of the air outlets/diffusers installed in the factory. The relative humidity data also showed very small differences along the height for all the three test conditions. The CO 2 measurement data over the period under all three test conditions are also presented and discussed. The CO 2 concentration was observed to be below the optimal threshold of 700 ppm for all three test conditions. The slightly higher CO 2 concentrations under the three conditions can be explained by the use of direct gas air heaters in the HVAC system during the heating season. The data show that the differences between the measured temperature and CO 2 values under different conditions are negligible, although the volumetric flow rate is reduced from approximately 62,000 m 3 /h to approximately 54,000 m 3 /h and 40,000 m 3 /h for the supply and exhaust air, respectively. The comparison of energy consumption among the three conditions revealed that condition C3 consumed less energy than condition C1, resulting in significant savings of 1,186 kWh. Additionally, condition C2, with a lower volumetric flow rate than the other two conditions, achieved a substantial energy savings of 11,611 kWh compared to condition C1. It was shown that electrical energy savings of over 60% could be achieved for the reduced flow rate, with no significant negative impact on the temperature, humidity, and CO2 concentration in the work areas. The results of this study can, in turn, be used for decision support or the optimization of HVAC systems. This approach using low-cost wireless sensors can provide an interesting way to combine spatially and temporally highly resolved measured data from the network of any given area with an appropriate control algorithm to create a dynamic control environment. The use case presented here shows this for three different outdoor and indoor air conditions in a large industrial environment, although a static-control approach was used. The sensors have benefits owing to their minimal deployment effort and should be further investigated in the future, for example, on a larger scale, in a different industrial area, or with a different control approach. In addition, an accurate comfort study can easily be conducted for any specific location. Different types of machinery used in the area can also be studied, as emissions such as volatile organic compounds (VOCs) can affect indoor air quality and should be considered in future studies. It should be noted that this study on reducing airflow rates by closely monitoring indoor air was carried out in consultation with the Health and Safety Authorities. Following the removal of the mobile sensor network at the end of the experiments, the factory fitted the hall with additional stationary sensors for temperature, humidity, CO 2 and NO x . By monitoring the data of these quantities and maintaining good climatic conditions in the hall, the airflow was gradually reduced to find an acceptable minimum close to the C2 condition, considering the technical requirements of the ventilation system. Finally, a specific air flow rate between 7 m 3 /(hm 2 ) and 9 m 3 /(hm 2 ), depending on the season, was determined for this assembly hall under the given conditions, resulting in an electrical power of approximately 3 kW per fan. Ethics and consent Ethical approval and consent were not required. Data availability statement Zenodo: Dataset for article submission 153972 in Journal F1000Research (1.0) [Data set], https://doi.org/10.5281/zenodo.13773811 ( Roesler, 2024 ). The project contains following underlying data (all in one xlsx-file including selected diagrams): • Energy demand of ventilators • Sensor data of air temperature and relative humidity • Sensor data of CO 2 -level Data are available under the terms of the Creative Commons Attribution 4.0 International license (CC BY 4.0). Acknowledgement We thank the experts from the energy management and technology of the factory in Września for many helpful discussions, much information from a practical point of view, and the management of the ventilation systems. References Arendt M, Haupt L, Kremonke A, et al. : Entwicklung eines vernetzten Systems zur Erfassung, Visualisierung und Auswertung von Messdaten sowie zur Ansteuerung von Aktoren – Teil 1. GI - Gebäudetechnik in Wissenschaft & Praxis. 2018; 2 : pp. 144–155. Bureau of Energy Efficiency: Fans and Blowers; Government of India. 4th Floor, Sewa Bhawan. R. K. Puram, New Delhi - 110066 (INDIA): Ministry of Power; 2023. Last visited: 11.02.2024 Reference Source Heiselberg P, Murakami S, Roulet C-A: Ventilation of Large Spaces in Buildings, Analysis and Prediction Technics. IEA, Energy Conservation in Buildings and Community Systems. Annex 26: Ventilation of Large Enclosures. ISSN 1395-7953 R9803. Aalborg, Denmark: Aalborg University; 1998. Reference Source Lan X, Tans P, Thoning K: Trends in globally-averaged CO2 determined from NOAA Global Monitoring Laboratory measurements. Version 2023-07.2023. Publisher Full Text Roesler M: Dataset for article submission 153972 in Journal F1000Research (1.0). [Data set]. Zenodo. 2024. Publisher Full Text VDI-Gesellschaft Bauen und Gebäudetechnik: Air conditioning systems for factories, Part 1. VDI Verein Deutscher Ingenieure e.V. Düsseldorf. 2014-09. Beuth-Verlag; 2014. VDI-Gesellschaft Bauen und Gebäudetechnik: Energy conservation by application of variable speed drives (VSD) in building services, VDI Verein Deutscher Ingenieure e.V. Düsseldorf. 2016-12. Beuth-Verlag; 2016. Volkswagen AG: Energy consumption distribution according to production areas and process [Unpublished data]. Volkswagen AG.2023. 2019 Weather History in Poznań, WeatherSpark.com, Cedar Lake Ventures, Inc: 2500 Shadywood Rd Ste 510 Excelsior, MN 55331-6203 United States.2019. Last visited: 11.02.2024. Reference Source 2022 Weather History in Poznań, WeatherSpark.com, Cedar Lake Ventures, Inc: 2500 Shadywood Rd Ste 510 Excelsior, MN 55331-6203 United States.2022. Last visited: 11.02.2024. Reference Source Comments on this article Comments (0) Version 2 VERSION 2 PUBLISHED 31 Oct 2024 ADD YOUR COMMENT Comment Author details Author details 1 Chair of Building Energy Systems and Heat Supply, Institute of Power Engineering, Technische Universität Dresden, Dresden, Saxony, Germany Yose Wandy Roles: Conceptualization, Data Curation, Formal Analysis, Visualization, Writing – Original Draft Preparation Ralf Gritzki Roles: Conceptualization, Formal Analysis, Software, Visualization, Writing – Original Draft Preparation Markus Rösler Roles: Methodology, Validation, Writing – Original Draft Preparation Alf Perschk Roles: Conceptualization, Data Curation, Software, Visualization Clemens Felsmann Roles: Methodology, Supervision, Validation, Writing – Review & Editing Competing interests No competing interests were disclosed. Grant information The Article Processing Charge (APC) were funded by the joint publication funds of the TU Dresden, including Carl Gustav Carus Faculty of Medicine, and the SLUB Dresden as well as the Open Access Publication Funding of the DFG. The funders had no role in study design, data collection and analysis, decision to publish, or preparation of the manuscript. Article Versions (2) version 2 Revised Published: 29 Apr 2026, 13:1309 https://doi.org/10.12688/f1000research.153972.2 version 1 Published: 31 Oct 2024, 13:1309 https://doi.org/10.12688/f1000research.153972.1 Copyright © 2024 Wandy Y et al . This is an open access article distributed under the terms of the Creative Commons Attribution License , which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited. Download Export To Sciwheel Bibtex EndNote ProCite Ref. Manager (RIS) Sente metrics Views Downloads F1000Research - - PubMed Central info_outline Data from PMC are received and updated monthly. - - Citations open_in_new 0 open_in_new 0 open_in_new SEE MORE DETAILS CITE how to cite this article Wandy Y, Gritzki R, Rösler M et al. Energy efficient heating and ventilation of a factory hall by monitoring the indoor air climate [version 1; peer review: 1 not approved] . F1000Research 2024, 13 :1309 ( https://doi.org/10.12688/f1000research.153972.1 ) NOTE: If applicable, it is important to ensure the information in square brackets after the title is included in all citations of this article. COPY CITATION DETAILS track receive updates on this article Track an article to receive email alerts on any updates to this article. TRACK THIS ARTICLE Share Open Peer Review Current Reviewer Status: ? Key to Reviewer Statuses VIEW HIDE Approved The paper is scientifically sound in its current form and only minor, if any, improvements are suggested Approved with reservations A number of small changes, sometimes more significant revisions are required to address specific details and improve the papers academic merit. Not approved Fundamental flaws in the paper seriously undermine the findings and conclusions Version 1 VERSION 1 PUBLISHED 31 Oct 2024 Views 0 Cite How to cite this report: Mishra AK. Reviewer Report For: Energy efficient heating and ventilation of a factory hall by monitoring the indoor air climate [version 1; peer review: 1 not approved] . F1000Research 2024, 13 :1309 ( https://doi.org/10.5256/f1000research.168941.r342001 ) The direct URL for this report is: https://f1000research.com/articles/13-1309/v1#referee-response-342001 NOTE: it is important to ensure the information in square brackets after the title is included in this citation. Close Copy Citation Details Reviewer Report 27 Nov 2024 Asit Kumar Mishra , University College Cork,, Cork, Ireland Not Approved VIEWS 0 https://doi.org/10.5256/f1000research.168941.r342001 This is an interesting work and well executed. I would strongly advise the energy part to be combined and made into a stronger paper. Also, please present the detailed workings. It would seem authors are assuming readers will somehow read ... Continue reading READ ALL This is an interesting work and well executed. I would strongly advise the energy part to be combined and made into a stronger paper. Also, please present the detailed workings. It would seem authors are assuming readers will somehow read their mind. Details regarding sensor positioning, which sensors went where, why, recirculation fraction, how did the changes impact indoor conditions, these need to be provided and discussed. Abstract - 120 sensors sounds like a big number without an idea on the floor space. Also, why not mention what kind of factory is being considered? Results in Abstract needs more values. How do readers understand that thermal comfort and IAQ were indeed not compromised? "vertical temperature gradients with higher temperatures in the upper hall area should be avoided to prevent energy loss." - this is not clear cut. What if i have a warm to cold gradient from floor to ceiling in a heating dominated climate. Why is that problematic? Introduction lacks reference to existing literature - what is the gap that authors are trying to address, has this approach really never been used? Table 1 and 2 - it is not clear how much of the supplied air is recirculated and how much is outdoor air "ventilator resps. fans" please avoid shortening words How did authors decide on position of the 120 sensors? This needs a clearer description. At first glance, it is not even apparent how many sensors of what type are present per unit floor area. We need to understand where each type of sensor is positioned and what is the SOP used to determine positioning. I am missing the recirculation vs outdoor air and corresponding change in energy usage discussion and results. "switching off the ventilation at night ..." do the floors receive outdoor air during night, when there is no worker on floor as well? Need some information on occupant activity (met rates) and clothing For a factory floor, particulate matter and VOC data would also be relevant. CO2 could work as a proxy but we are not sure how good of a proxy it would be I am not sure why the energy saved for heating (gas) is part of another publication? Also, I would like to see some discussion on how things changed when the flow was reduced - the conditions still seem comfortable but there were some changes as would be expected when you reduce the air supply. This needs to be analyzed. Were there any feedback from the people working on the floors? Is the work clearly and accurately presented and does it cite the current literature? No Is the study design appropriate and is the work technically sound? Yes Are sufficient details of methods and analysis provided to allow replication by others? No If applicable, is the statistical analysis and its interpretation appropriate? Partly Are all the source data underlying the results available to ensure full reproducibility? No Are the conclusions drawn adequately supported by the results? Partly Competing Interests: No competing interests were disclosed. Reviewer Expertise: indoor climate monitoring and optimization, indoor climate and occupant health, sustainable indoor conditioning, healthy buildings I confirm that I have read this submission and believe that I have an appropriate level of expertise to state that I do not consider it to be of an acceptable scientific standard, for reasons outlined above. Close READ LESS CITE CITE HOW TO CITE THIS REPORT Mishra AK. Reviewer Report For: Energy efficient heating and ventilation of a factory hall by monitoring the indoor air climate [version 1; peer review: 1 not approved] . F1000Research 2024, 13 :1309 ( https://doi.org/10.5256/f1000research.168941.r342001 ) The direct URL for this report is: https://f1000research.com/articles/13-1309/v1#referee-response-342001 NOTE: it is important to ensure the information in square brackets after the title is included in all citations of this article. COPY CITATION DETAILS Report a concern Author Response 07 Apr 2026 Markus Rösler , Chair of Building Energy Systems and Heat Supply, Institute of Power Engineering, Technische Universität Dresden, Dresden, Germany 07 Apr 2026 Author Response We would like to sincerely thank the reviewer for his valuable remarks and suggestions to improve the manuscript. Especially the remark, that we assume readers could read our mind to ... Continue reading We would like to sincerely thank the reviewer for his valuable remarks and suggestions to improve the manuscript. Especially the remark, that we assume readers could read our mind to understand some details inspired us to better explain the ideas behind and the scientific background. All reviewer comments have been addressed. The changes referenced below resulted in the revised version of the manuscript (version 2), which is currently under submission. Detailed responses to reviewer comments follow: In the abstract we added the data of the industrial hall that the reader can imagine that it is actually a large enclosure. And we give a short explanation why thermal comfort and IAQ are not compromised after reduction of air flow rates. We are better discussing the vertical temperature gradients and its significance for the indoor air climate in the introduction section and we added two references where similar approaches are used to identify the indoor air flow pattern and indoor air climate in large spaces. Because of some special conditions recirculating air was not an option in our investigation, instead, heat recovery was used. We address it in the methods section. The distribution of 120 sensors was indeed a challenge. In the methods section we explain the ideas behind and the scientific background how we selected four representative cells for sensor installation. We added information about occupant activity and clothing. And we address, that we of course used the feedback of the workers to improve the ventilation situation. The reviewer is completely right that VOC is also of interest in an industrial hall. But it was not part of our investigation and was monitored by health and safety authorities. The key point, the key insight was also addressed by the reviewer, thank you very much. How can it happen, that air flow rates are considerable reduced and the conditions are still the same? Under results & discussion we improved our explanation that heating mainly comes from inner gains and the incoming air is only pre-warmed. Therefore, the air goes with slightly lower temperature downwards and changes in the air flow rates can be balanced by changes in the pre-warming of the incoming air. The indoor air flow pattern remains nearly the same and also the temperature distribution. This is of course only possible because of the well-designed ventilation system and very good thermal insulation of the building. We emphasize this more in the new version of the paper. Finally, we cancelled some paragraphs, improved language, did some small corrections and uploaded an improved version of the dataset on zenodo. We would like to sincerely thank the reviewer for his valuable remarks and suggestions to improve the manuscript. Especially the remark, that we assume readers could read our mind to understand some details inspired us to better explain the ideas behind and the scientific background. All reviewer comments have been addressed. The changes referenced below resulted in the revised version of the manuscript (version 2), which is currently under submission. Detailed responses to reviewer comments follow: In the abstract we added the data of the industrial hall that the reader can imagine that it is actually a large enclosure. And we give a short explanation why thermal comfort and IAQ are not compromised after reduction of air flow rates. We are better discussing the vertical temperature gradients and its significance for the indoor air climate in the introduction section and we added two references where similar approaches are used to identify the indoor air flow pattern and indoor air climate in large spaces. Because of some special conditions recirculating air was not an option in our investigation, instead, heat recovery was used. We address it in the methods section. The distribution of 120 sensors was indeed a challenge. In the methods section we explain the ideas behind and the scientific background how we selected four representative cells for sensor installation. We added information about occupant activity and clothing. And we address, that we of course used the feedback of the workers to improve the ventilation situation. The reviewer is completely right that VOC is also of interest in an industrial hall. But it was not part of our investigation and was monitored by health and safety authorities. The key point, the key insight was also addressed by the reviewer, thank you very much. How can it happen, that air flow rates are considerable reduced and the conditions are still the same? Under results & discussion we improved our explanation that heating mainly comes from inner gains and the incoming air is only pre-warmed. Therefore, the air goes with slightly lower temperature downwards and changes in the air flow rates can be balanced by changes in the pre-warming of the incoming air. The indoor air flow pattern remains nearly the same and also the temperature distribution. This is of course only possible because of the well-designed ventilation system and very good thermal insulation of the building. We emphasize this more in the new version of the paper. Finally, we cancelled some paragraphs, improved language, did some small corrections and uploaded an improved version of the dataset on zenodo. Competing Interests: No competing interests were disclosed. Close Report a concern Respond or Comment COMMENTS ON THIS REPORT Author Response 07 Apr 2026 Markus Rösler , Chair of Building Energy Systems and Heat Supply, Institute of Power Engineering, Technische Universität Dresden, Dresden, Germany 07 Apr 2026 Author Response We would like to sincerely thank the reviewer for his valuable remarks and suggestions to improve the manuscript. Especially the remark, that we assume readers could read our mind to ... Continue reading We would like to sincerely thank the reviewer for his valuable remarks and suggestions to improve the manuscript. Especially the remark, that we assume readers could read our mind to understand some details inspired us to better explain the ideas behind and the scientific background. All reviewer comments have been addressed. The changes referenced below resulted in the revised version of the manuscript (version 2), which is currently under submission. Detailed responses to reviewer comments follow: In the abstract we added the data of the industrial hall that the reader can imagine that it is actually a large enclosure. And we give a short explanation why thermal comfort and IAQ are not compromised after reduction of air flow rates. We are better discussing the vertical temperature gradients and its significance for the indoor air climate in the introduction section and we added two references where similar approaches are used to identify the indoor air flow pattern and indoor air climate in large spaces. Because of some special conditions recirculating air was not an option in our investigation, instead, heat recovery was used. We address it in the methods section. The distribution of 120 sensors was indeed a challenge. In the methods section we explain the ideas behind and the scientific background how we selected four representative cells for sensor installation. We added information about occupant activity and clothing. And we address, that we of course used the feedback of the workers to improve the ventilation situation. The reviewer is completely right that VOC is also of interest in an industrial hall. But it was not part of our investigation and was monitored by health and safety authorities. The key point, the key insight was also addressed by the reviewer, thank you very much. How can it happen, that air flow rates are considerable reduced and the conditions are still the same? Under results & discussion we improved our explanation that heating mainly comes from inner gains and the incoming air is only pre-warmed. Therefore, the air goes with slightly lower temperature downwards and changes in the air flow rates can be balanced by changes in the pre-warming of the incoming air. The indoor air flow pattern remains nearly the same and also the temperature distribution. This is of course only possible because of the well-designed ventilation system and very good thermal insulation of the building. We emphasize this more in the new version of the paper. Finally, we cancelled some paragraphs, improved language, did some small corrections and uploaded an improved version of the dataset on zenodo. We would like to sincerely thank the reviewer for his valuable remarks and suggestions to improve the manuscript. Especially the remark, that we assume readers could read our mind to understand some details inspired us to better explain the ideas behind and the scientific background. All reviewer comments have been addressed. The changes referenced below resulted in the revised version of the manuscript (version 2), which is currently under submission. Detailed responses to reviewer comments follow: In the abstract we added the data of the industrial hall that the reader can imagine that it is actually a large enclosure. And we give a short explanation why thermal comfort and IAQ are not compromised after reduction of air flow rates. We are better discussing the vertical temperature gradients and its significance for the indoor air climate in the introduction section and we added two references where similar approaches are used to identify the indoor air flow pattern and indoor air climate in large spaces. Because of some special conditions recirculating air was not an option in our investigation, instead, heat recovery was used. We address it in the methods section. The distribution of 120 sensors was indeed a challenge. In the methods section we explain the ideas behind and the scientific background how we selected four representative cells for sensor installation. We added information about occupant activity and clothing. And we address, that we of course used the feedback of the workers to improve the ventilation situation. The reviewer is completely right that VOC is also of interest in an industrial hall. But it was not part of our investigation and was monitored by health and safety authorities. The key point, the key insight was also addressed by the reviewer, thank you very much. How can it happen, that air flow rates are considerable reduced and the conditions are still the same? Under results & discussion we improved our explanation that heating mainly comes from inner gains and the incoming air is only pre-warmed. Therefore, the air goes with slightly lower temperature downwards and changes in the air flow rates can be balanced by changes in the pre-warming of the incoming air. The indoor air flow pattern remains nearly the same and also the temperature distribution. This is of course only possible because of the well-designed ventilation system and very good thermal insulation of the building. We emphasize this more in the new version of the paper. Finally, we cancelled some paragraphs, improved language, did some small corrections and uploaded an improved version of the dataset on zenodo. Competing Interests: No competing interests were disclosed. Close Report a concern COMMENT ON THIS REPORT Comments on this article Comments (0) Version 2 VERSION 2 PUBLISHED 31 Oct 2024 ADD YOUR COMMENT Comment keyboard_arrow_left keyboard_arrow_right Open Peer Review Reviewer Status info_outline Alongside their report, reviewers assign a status to the article: Approved The paper is scientifically sound in its current form and only minor, if any, improvements are suggested Approved with reservations A number of small changes, sometimes more significant revisions are required to address specific details and improve the papers academic merit. Not approved Fundamental flaws in the paper seriously undermine the findings and conclusions Reviewer Reports Invited Reviewers 1 Version 2 (revision) 29 Apr 26 Version 1 31 Oct 24 read Asit Kumar Mishra , University College Cork,, Cork, Ireland Comments on this article All Comments (0) Add a comment Sign up for content alerts Sign Up You are now signed up to receive this alert Browse by related subjects keyboard_arrow_left Back to all reports Reviewer Report 0 Views copyright © 2024 Mishra A. This is an open access peer review report distributed under the terms of the Creative Commons Attribution License , which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited. 27 Nov 2024 | for Version 1 Asit Kumar Mishra , University College Cork,, Cork, Ireland 0 Views copyright © 2024 Mishra A. This is an open access peer review report distributed under the terms of the Creative Commons Attribution License , which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited. format_quote Cite this report speaker_notes Responses (1) Not Approved info_outline Alongside their report, reviewers assign a status to the article: Approved The paper is scientifically sound in its current form and only minor, if any, improvements are suggested Approved with reservations A number of small changes, sometimes more significant revisions are required to address specific details and improve the papers academic merit. Not approved Fundamental flaws in the paper seriously undermine the findings and conclusions This is an interesting work and well executed. I would strongly advise the energy part to be combined and made into a stronger paper. Also, please present the detailed workings. It would seem authors are assuming readers will somehow read their mind. Details regarding sensor positioning, which sensors went where, why, recirculation fraction, how did the changes impact indoor conditions, these need to be provided and discussed. Abstract - 120 sensors sounds like a big number without an idea on the floor space. Also, why not mention what kind of factory is being considered? Results in Abstract needs more values. How do readers understand that thermal comfort and IAQ were indeed not compromised? "vertical temperature gradients with higher temperatures in the upper hall area should be avoided to prevent energy loss." - this is not clear cut. What if i have a warm to cold gradient from floor to ceiling in a heating dominated climate. Why is that problematic? Introduction lacks reference to existing literature - what is the gap that authors are trying to address, has this approach really never been used? Table 1 and 2 - it is not clear how much of the supplied air is recirculated and how much is outdoor air "ventilator resps. fans" please avoid shortening words How did authors decide on position of the 120 sensors? This needs a clearer description. At first glance, it is not even apparent how many sensors of what type are present per unit floor area. We need to understand where each type of sensor is positioned and what is the SOP used to determine positioning. I am missing the recirculation vs outdoor air and corresponding change in energy usage discussion and results. "switching off the ventilation at night ..." do the floors receive outdoor air during night, when there is no worker on floor as well? Need some information on occupant activity (met rates) and clothing For a factory floor, particulate matter and VOC data would also be relevant. CO2 could work as a proxy but we are not sure how good of a proxy it would be I am not sure why the energy saved for heating (gas) is part of another publication? Also, I would like to see some discussion on how things changed when the flow was reduced - the conditions still seem comfortable but there were some changes as would be expected when you reduce the air supply. This needs to be analyzed. Were there any feedback from the people working on the floors? Is the work clearly and accurately presented and does it cite the current literature? No Is the study design appropriate and is the work technically sound? Yes Are sufficient details of methods and analysis provided to allow replication by others? No If applicable, is the statistical analysis and its interpretation appropriate? Partly Are all the source data underlying the results available to ensure full reproducibility? No Are the conclusions drawn adequately supported by the results? Partly Competing Interests No competing interests were disclosed. Reviewer Expertise indoor climate monitoring and optimization, indoor climate and occupant health, sustainable indoor conditioning, healthy buildings I confirm that I have read this submission and believe that I have an appropriate level of expertise to state that I do not consider it to be of an acceptable scientific standard, for reasons outlined above. reply Respond to this report Responses (1) Author Response 07 Apr 2026 Markus Rösler, Chair of Building Energy Systems and Heat Supply, Institute of Power Engineering, Technische Universität Dresden, Dresden, Germany We would like to sincerely thank the reviewer for his valuable remarks and suggestions to improve the manuscript. Especially the remark, that we assume readers could read our mind to understand some details inspired us to better explain the ideas behind and the scientific background. All reviewer comments have been addressed. The changes referenced below resulted in the revised version of the manuscript (version 2), which is currently under submission. Detailed responses to reviewer comments follow: In the abstract we added the data of the industrial hall that the reader can imagine that it is actually a large enclosure. And we give a short explanation why thermal comfort and IAQ are not compromised after reduction of air flow rates. We are better discussing the vertical temperature gradients and its significance for the indoor air climate in the introduction section and we added two references where similar approaches are used to identify the indoor air flow pattern and indoor air climate in large spaces. Because of some special conditions recirculating air was not an option in our investigation, instead, heat recovery was used. We address it in the methods section. The distribution of 120 sensors was indeed a challenge. In the methods section we explain the ideas behind and the scientific background how we selected four representative cells for sensor installation. We added information about occupant activity and clothing. And we address, that we of course used the feedback of the workers to improve the ventilation situation. The reviewer is completely right that VOC is also of interest in an industrial hall. But it was not part of our investigation and was monitored by health and safety authorities. The key point, the key insight was also addressed by the reviewer, thank you very much. How can it happen, that air flow rates are considerable reduced and the conditions are still the same? Under results & discussion we improved our explanation that heating mainly comes from inner gains and the incoming air is only pre-warmed. Therefore, the air goes with slightly lower temperature downwards and changes in the air flow rates can be balanced by changes in the pre-warming of the incoming air. The indoor air flow pattern remains nearly the same and also the temperature distribution. This is of course only possible because of the well-designed ventilation system and very good thermal insulation of the building. We emphasize this more in the new version of the paper. Finally, we cancelled some paragraphs, improved language, did some small corrections and uploaded an improved version of the dataset on zenodo. View more View less Competing Interests No competing interests were disclosed. reply Respond Report a concern Mishra AK. Peer Review Report For: Energy efficient heating and ventilation of a factory hall by monitoring the indoor air climate [version 1; peer review: 1 not approved] . F1000Research 2024, 13 :1309 ( https://doi.org/10.5256/f1000research.168941.r342001) NOTE: it is important to ensure the information in square brackets after the title is included in this citation. 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