Case Study: Cotton On Distribution Warehouse & Jet Black Fan Systems

Background

Cotton On set out to transform the working environment at their new distribution warehouse by enhancing air circulation and cooling for staff. Their objective was to create a more comfortable and productive workspace while overcoming limitations experienced in their previous facility. The key priorities at the new site included reducing noise, lowering energy consumption, and improving airflow to support staff satisfaction and retention.

Challenges

In their former warehouse, Cotton On relied on individual workstation fans, which presented several operational and environmental drawbacks:

• Excessive Noise: The fans were loud, disrupting focus and overall productivity.
• High Energy Usage: The cumulative power draw from multiple fans significantly increased energy costs.
• Power Access Constraints: The need for numerous outlets and extension cords created logistical challenges and potential safety hazards.
• Inefficient Cooling: The fans produced high-velocity airflow that was uneven and uncomfortable, rather than delivering a consistent, gentle breeze.

Cotton On needed a scalable, low-maintenance solution that would provide consistent airflow, reduce energy usage, and operate quietly.

Solution

To meet these requirements, four Powerfoil X4 Big Ass Fans were installed across key areas of the new distribution warehouse, including central workstations and the packing zone. Jet Black Fan Systems recommended these HVLS fans for their proven performance in delivering large volumes of air quietly and efficiently. The strategic placement of the fans ensured optimal coverage and uniform airflow throughout the facility.

Results

• Enhanced Climate Control & Energy Efficiency: Seven months post-installation, the fans have noticeably improved air quality and comfort. During winter, they run at low speeds to circulate warm air downwards (destratification). In summer, they operate daily from 2 AM to 9 PM to maintain a steady, cool airflow. Even at full power, the fans are virtually silent, resolving the noise issues of the previous setup.
• Performance Beyond Expectations: The scale and effectiveness of the Powerfoil X4 fans have exceeded initial expectations. They consistently deliver a refreshing breeze across the warehouse, drawing positive feedback from both staff and visitors.
• Staff Comfort & Productivity: The significantly cooler working environment, especially in summer, has boosted employee comfort and productivity—key outcomes for warehouse operations.
• Cost Savings: The transition to high-efficiency ceiling fans has resulted in measurable energy savings by eliminating the need for numerous portable fans and extension leads. Cotton On now benefits from lower energy bills and simplified infrastructure.

Client Testimonial

"The Jet Black team has been amazing to work with, from accounts to installation. The fans are powerful, quiet, and have made a huge difference in both the comfort and efficiency of our warehouse."

Conclusion

The installation of Big Ass Fans at Cotton On’s new distribution warehouse has proven to be a strategic investment. By adopting an energy-efficient, low-noise cooling solution, Cotton On has elevated staff well-being, streamlined operations, and reduced long-term energy costs. The collaboration with Jet Black Fan Systems has set a new benchmark for airflow solutions in large-scale warehousing environments.

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