Case Study: Keeping a Mexican Flooring Factory Cool with Rare-Earth Radiative Coatings
Location: Nexxus ADN 2 Industrial Park, Ciénegas de Flores, Nuevo León, Mexico
Sector: Industrial manufacturing (SPC/WPC/Vinyl flooring)
Project Snapshot
- Problem: Extreme summer heat and long sun hours caused high indoor temperatures, energy costs, and quality risks.
- Roof Build-Up: ~95% KR-18 galvanized steel; ~5% polycarbonate skylight domes.
- Internal Loads: MF equipment operating up to ~180 °C.
- Goal: Passive temperature control to reduce cooling energy and improve working conditions.
Why It’s Hot Inside
- Climate: Peak ambient up to ~46–47 °C; strong solar intensity (8–10+ sun hours/day in summer).
- Metal Roof Physics: High thermal conductivity and “thermal bridge” effects accelerate heat transfer; aging/oxidation lowers reflectance.
- Skylight Domes: High transmittance funnels solar gain; dome geometry can trap hot air (“chimney effect”).
- Process Heat: Equipment adds sustained internal heat, stressing HVAC and workers.
The EASYTO TCRC Strategy (Temperature Control for Reducing Consumption)
A passive cooling retrofit pairing rare-earth radiative-cooling coatings on metal roof areas with a transparent liquid coating on skylights. Once applied, the system blocks/reflects NIR & UV and emits heat through the atmospheric window, lowering surface and indoor temperatures without ongoing power input.
Two Retrofit Options
Option 1 — Gen-5 Silicon-Acrylic (Balanced Performance & Budget)
- Metal Roof: Epoxy primer + Gen-5 silicon-acrylic radiative-cooling layer + hydrophobic topcoat (spray/roll/brush).
- Skylights: Smart1098™ liquid glass coating (inside or outside single coat, spray applied).
- Expected Impact: Roof surface −20~30 °C; indoor air ~−9.7 °C; skylight zone −7~15 °C; 25–40% cooling energy savings.
Option 2 — Gen-7 Fluorocarbon (Maximum Durability & Performance)
- Metal Roof: Epoxy primer + Gen-7 fluorocarbon radiative-cooling layer + hydrophobic/oleophobic topcoat.
- Skylights: Smart1098™ liquid glass coating (as above).
- Expected Impact: Similar temperature reductions with enhanced UV, corrosion, and weather resistance for long service life.
How the Technology Works
- Rare-Earth LSPR: Special 4f-orbital resonance blocks IR/UV while maintaining visible light clarity.
- Radiative Cooling: Coatings re-emit heat through the “sky window,” passively rejecting heat to space.
- Transparent Skylight Upgrade: Smart1098™ adds IR/UV rejection without sacrificing daylight.
Benefits to Operations
- Energy & Cost: 25–40% cooling load reduction; cuts peak demand and runtime.
- Comfort & Safety: Cooler shop floor, lower risk of heat stress, better focus and productivity.
- Quality & Uptime: More stable line temperatures help consistency in extrusion/calendering; reduced risk of defects.
- Durability: Weatherable topcoats resist UV, water, oil, and contaminants; extend roof life.
- Sustainability: Passive solution supports carbon and ESG goals.
Application Overview
- Roof preparation: clean, de-rust, ensure dry/solid substrate; repair joints/seams.
- Primer: epoxy system to enhance adhesion and barrier performance.
- Functional layer: Gen-5 (silicon-acrylic) or Gen-7 (fluorocarbon) radiative-cooling coat.
- Topcoat: hydrophobic/oleophobic finish for self-cleaning and long-term durability.
- Skylights: spray-apply Smart1098™ transparent liquid coating (single-side coat).
- QC & Handover: dry film thickness checks; adhesion and appearance inspection.
Key Metrics to Track
- Roof surface temperature (pre/post, midday clear sky)
- Indoor dry-bulb at fixed sensor points (pre/post)
- Chiller/compressor runtime and kWh consumption
- Worker heat-stress incidents and comfort surveys
- Product defect rates linked to thermal variance
Results You Can Expect
In similar deployments, EASYTO systems have delivered roof surface drops of 20–30 °C, indoor reductions around 9–10 °C, 7–15 °C cooler skylight zones, and 25–40% savings in cooling energy—all while preserving daylight and improving occupant comfort.
