The Science ▪ AirMotion Next Generation HVLS Fans ▪ Applications ▪ About AirMotion ▪ FAQ


Who is AirMotion Sciences?

AirMotion Sciences, Inc. is a Massachusetts, USA based technology company making Big Smart Fans™ - the Next Generation HVLS (High Volume Low Speed) fans, an energy efficient air movement system - for large industrial, agricultural, commercial, and other high roof facilities/buildings to help them increase productivity and operational efficiency by improving the facility environment (through cooling, heat destratification, supplementing Air Conditioning, and ventilation) in all seasons and climates while reducing HVAC energy costs significantly.

The company was founded in 2006 by Peter D. Caruso (former CEO and President of MacroAir Technologies, LLC), with the objective to 'build a better mousetrap' by significantly improving upon existing HVLS technology. Mr. Caruso’s experience in the HVLS fan industry was crucial in assembling an expert engineering team for the company. As a family-run business he has always ensured product quality and customer service are at the core of the company’s development efforts and day to day operations. The innovation that he and his experienced team have made in HVLS technology are a testament to AirMotion's efforts as their Big Smart Fans raise the bar in the big fan industry by significantly advancing the technology to the next generation of HVLS fans.


What is HVLS (High Volume Low Speed) technology?

HVLS technology works on a simple air movement concept. On a hot, humid day you feel cool when a breeze is blowing; the breeze causes evaporation of moisture on your skin surface and you do not need to be a rocket scientist to know that evaporation takes away the latent heat off your skin so you feel cool. Air has significant mass, and once it starts moving - as inertia is overcome - the momentum of the moving air mass allows for a continuous air circulation requiring little effort to maintain it. HVLS fans - with their large blades and low speed - move and mix large masses of air using very little energy as low speed air motion requires less energy (the larger size of HVLS fans help create larger flows of air that have proportionally less surface area and therefore encounter less friction and related drag, which allows the air to move further using less energy and effort than the standard 36 inches high-speed fans).

It is common knowledge in fan design that the power required to drive a fan varies approximately with the cube of the average air speed through the fan - i.e. doubling the air speed requires eight times the power. Accordingly, a fan delivering air at 20 mph requires 64 times as much power as one delivering air at 5 mph. While a breeze blowing over our skin makes us feel cool and comfortable, high speed air movement does not provide any additional cooling and is often very unlikable and disruptive (hence undesirable). HVLS fans have become an effective and cost efficient air movement solution in many large facilities for cooling, heat destratification, supplementing Air Conditioning, and ventilation. They are much more effective and energy efficient than the high-speed standard industrial fans (one HVLS fan can replace many high-speed fans) and provide quick payback and high return on investment through significant energy savings.


What is AirMotion Big Smart Fan™ or Next Generation HVLS fan?

Applying the concepts of fluid dynamics with smart technologies and expert engineering, AirMotion Sciences has developed Big Smart Fans - the next generation of High Volume Low Speed (HVLS) fans. AirMotion Big Smart Fans are purposely designed to be 9 ft, 12 ft, and 15 ft in diameter with a low profile design and packed with the smartest features in the big fan industry - like, Variable Pitch Technology (VPT™), Rotatair™ Composite blades, and MultiMode Smart Control capability - to provide a complete and more effective air movement throughout a facility than the old generation larger HVLS fans. The fans are easy to install and operate, use very little energy and last a long trouble-free life. Their innovative sizes do not hinder the most common lighting and fire suppression setups, and low profile design helps them fit in any applications including lower roof facility areas as well as above cranes and other areas where space is tight. They are operated from a low voltage MultiMode Smart Control unit which is installed at the ground level controlling the fan speed, blade pitch angle, power on/off, and five operating modes of the fan. The fans use six Rotatair™ blades made of composite material - they are stronger yet lighter in weight than the standard aluminum blades, and optimally shaped to be wider near the hub of the fan and narrower at the tips ensuring low turbulence and allowing fluid air movement across the fan. Unlike other blades with airfoil shape AirMotion's Rotatair Composite blades are symmetrical for equal effectiveness in moving air up or down.


What is VPT™ (Variable Pitch Technology)?

The most advanced feature of AirMotion Big Smart Fans is the Variable Pitch Technology (VPT™). It lets you change the blade pitch from 0° to 20° - up or down - to blow air in a columnar flow for narrower focus or conically disperse it for broader reach - we call it Adjustable Air Movement. The symmetry of the Rotatair blades ensures 100% upward or downward air movement. With three or more fans arranged in an array you can get an all-encompassing, wave like air movement and mixing throughout your facility by adjusting some fans to move the air upward while others moving the air downward. We call it Complete Facility Movement of air.

Our state-of-the-art application of Variable Frequency Drives (VFD) enables the fans to run at varying speeds (from 20 to 120 RPM). With the use of VFD and VPT together the fans can be adjusted to move the maximum amount of air within any given facility.


What are the key benefits of AirMotion Big Smart Fans/Next Generation HVLS fan?

The benefits that AirMotion big fans’ quiet and unobtrusive operation provides are multiple, and more than expected. Actually the benefits of AirMotion Next Generation HVLS Fans are some of the best things one can provide for a facility... in summer - winter - spring - fall - north - south - east - west - whenever, wherever.

  • A comfortable facility environment is critical for optimal productivity. AirMotion big fans provide a natural cooling effect of 6°F to 8°F or more by creating a pleasing, non-disruptive breeze - such as can be felt by the seaside - for happier, healthier, more productive facility staff (or barn animals in agricultural applications) while significantly reducing HVAC energy bills in the summertime (by replacing up to 15 or more high-speed standard industrial fans).

  • In the colder months, better heating comfort can be obtained at high-roof facilities with heaters installed at the roof level or at the floor level by running AirMotion big fans at lower speeds and/or altered pitch - including blowing air upwards - to bring trapped warmer air from the roof level down to the floor level (as hot air always goes up) and maintain a uniform temperature throughout the facility, while saving 20% or more in heating costs by reducing heater cycle time.

  • AirMotion big fans are a very effective supplement to Air Conditioning. They enable 3°F to 8°F thermostat increases by creating equivalent cooling effect of lower temperature settings with widespread air mixing, and provide 3% - 5% energy savings per degree.

  • AirMotion big fans efficiently and more effectively mix incoming fresh air with the indoor stale air to maintain a refreshing and healthier environment reducing/eliminating the need for any IAQ (Indoor Air Quality) solutions while also minimizing the volume of air (and corresponding loss of warm or cool air) that needs to be replaced.

  • The massive air movement of AirMotion big fans also replace humid and noxious air to create a healthier indoor atmosphere to breathe in; and reduce damage, waste, and disease with improved drying effect in dairies, warehouses, and food processing facilities. They also help keep birds and bugs away and eliminate all the damages that they cause.


What about the energy saving benefits?

Apart from the primary function of providing a comfortable and more productive facility environment, AirMotion big fans provide quick payback and high return on investment through significant energy savings by replacing lots of less energy efficient and less effective high-speed standard industrial fans (one AirMotion big fan can replace 15 high-speed fans), by circulating otherwise wasted heat in colder seasons/climates (eliminating stratification of heat), and by effectively supplementing Air Conditioning (keeping people as cool with widespread air mixing at higher thermostat settings).


Give me some numbers to digest.

Each fan costs about a nickel an hour to operate, using about as much energy as three or four light bulbs.

Savings versus using standard high-speed industrial fans
It is estimated that it would take at least 15 high-speed 0.5 hp 36" fans (or twelve 48" fans) to accomplish the same cooling effect of one 15 ft 1.5 hp AirMotion Big Smart Fan per 10,000 square feet of a typical 100,000 sq ft distribution center in Oklahoma City. The annual electrical operating costs over six months of those 15 high-speed fans would be approximately $2,376, versus $302 for the one AirMotion big fan. The difference in installed cost of the 15 high-speed fans is estimated to be $1000 less than the installed cost of one AirMotion big fan.

Accordingly, payback of the cost difference is less than a year ($2,074 annual savings versus incremental installation cost of $1000). Full payback on the installed cost of one AirMotion Big Smart Fan as a cooling alternative is less than 3 years. The NPV (Net Present Value) over 10 years would be about $15,000 per AirMotion big fan (not to mention that high-speed fans will most likely require frequent maintenance and replacement). Cooling 100,000 square feet of distribution facility means big savings with the big fans. In addition, the AirMotion Big Smart Fans provide more effective cooling for greater employee comfort and productivity.

Savings from Heat De-stratification
In a typical 100,000 sq ft distribution center near Boston with a 30 ft ceiling height, one can expect a payback period of less than a year on an estimated installed cost of $27,500 for five Big Smart Fans (more fans may be necessary if the prime objective is cooling, fewer are needed for heat destratification alone).

In this example, heating degree-days are estimated to be 5,630 such that natural gas is estimated to cost $158,000 annually (higher for other fuel sources). It is also estimated that there is at least a 15°F difference in temperature between the floor and roof level (more of a heat strata difference is often encountered).

Air mixing by AirMotion big fans creates a uniform temperature that reduces the frequency of heater cycling and cuts heat lost by infiltration through the roof (especially by taking advantage of our Variable Pitch Technology to effect what we call Complete Facility Movement of air) and save 20% to 37.5% in heating costs.

Even more savings are possible - it is estimated that there is an additional 10% in realizable savings from heat de-stratification for every 10 ft of additional height, and for every 5 additional degrees of temperature difference.

Using only 20% as an estimate for this example, there is nearly $32,000 in annual savings that can be realized. The annual ROI (Return On Investment) would be over 100%. The NPV (Net Present Value) of the savings over a 10 year period at 6% on such an investment (assuming no further increases in energy costs, which is unlikely, and little or no maintenance or component replacement, which is a realistic expectation) would be about $210,000. That means, a company would be wasting $210,000 over 10 years by not making the $27,500 investment in AirMotion Big Smart Fans today.

Savings as an alternative to air conditioning
The same 100,000 sq ft distribution center in Oklahoma City is estimated to require 200 tons of air conditioning at an installed cost of approximately $300,000. The annual maintenance would be estimated to be about $7,000 and the annual operating costs would be estimated to be $24,000. Compare the above to the estimated installed cost of about $55,000 for 10 AirMotion Big Smart Fans having an operating cost during the cooling season of about $3,000. AirMotion Big Smart Fans would be over $240,000 less expensive to install and $27,000 cheaper to run every year.


Where can these fans be installed?

Any large, high-roof facilities/buildings with high HVAC energy costs can benefit from AirMotion Big Smart Fans, including -

  • Distribution center and warehousing facilities

  • Manufacturing facilities like aviation facilities (airplane manufacturing/assembly plants, hangars, maintenance and service centers etc.), automotive facilities (manufacturing/assembly, dealerships, service centers etc.), municipal transportation and other facilities, and any large production, service or maintenance facilities (from boat manufacturing to precision instruments)

  • Commercial facilities like shopping malls/large retail outlets, fitness centers/gyms, indoor sports facilities/arena/equestrian center, auditoriums/lobbies/bars/restaurants, exhibition and convention centers, museums/churches/schools and colleges, airports/Fixed-base operators (FBOs) etc.

  • Agricultural operations like dairy/poultry, barn/ranch, food processing industries/fresh produces storage and packing facilities, wineries (AirMotion big fans help maintain consistent temperature - with built in temperature sensors - in the barrel storage areas of wineries)


Why should I buy AirMotion Big Smart Fans?

AirMotion Big Smart Fans™ are the Next Generation HVLS fans packed with the smartest features in the big fan industry like our proprietary VPT™ (Variable Pitch Technology), Rotatair™ Composite blades, and MultiMode Smart Control - probably the most efficient, cost-effective, and innovative way to improve the facility environment for enhanced comfort and increased productivity and operational efficiency by mixing and moving massive amounts of air while reducing HVAC energy costs significantly in all seasons and climates. Compared to AirMotion Big Smart Fans, most solutions - including the high-speed standard industrial fans - are less effective, or more expensive, or both.

Unlike any other big fans AirMotion Big Smart Fans provide you Adjustable Air Movement with one fan, and Complete Facility Movement of air with multiple fans arranged in an array at your facility by using Variable Pitch Technology (VPT™). They move large masses of air up and down, and de-stratify uneven temperatures trapped in different levels and zones to provide a complete and more effective air movement throughout your facility than the old generation larger HVLS fans to create more comfortable and healthier environment in all types of facilities. They are designed and capable to provide bigger performance yet built smaller with a low profile design allowing them to be installed in any applications including lower roof facility areas as well as above cranes and other areas where space is tight. AirMotion Big Smart Fans are easy to operate - you get manual to fully automatic fan control in 5 operating modes using MultiMode Smart Control, and with Rotatair™ composite blades and simple mounting hardware are lightweight and easy to install (complexity similar to a light fixture).

AirMotion customers leave a smaller carbon footprint by reducing their energy usage substantially. With smart technology and concepts, AirMotion Sciences is creating a revolution in air movement solutions, making the Next Generation HVLS fans not only a smart business decision, but a conscientious one as well. We are proud of our big fans. We know you won't be disappointed.


How do you relate comfort and productivity?

Apart from energy efficiency and cost savings benefits, the primary function of AirMotion Big Smart Fans is to provide comfort in a facility - more efficiently and effectively than any other air movement solutions. Enhancing comfort within a facility renders an increase in the level of worker and/or livestock productivity. Thus you get happier people (comfortable people are always happier and more productive) and more productivity all while reducing HVAC energy costs significantly.


Well, tell me about the 'green benefits' of AirMotion Next Generation HVLS fans.

AirMotion Sciences makes energy efficient air movement systems for large facilities/buildings with high HVAC energy costs to help them reduce energy usage while enhancing comfort and increasing productivity and operational efficiency. Apart from the financial benefits, reduced energy usage and corresponding greenhouse gas (GHG) emissions makes for a greener environment now and for future generations. We think AirMotion Big Smart Fans are one of the fastest, easiest, least expensive, and smartest ways for facilities to go green when compared with other technologies like wind power or solar energy. Unlike these big and expensive ideas with decade-long payback period, AirMotion HVLS fans start saving energy and the planet immediately.


Your fan sizes are relatively smaller, what would you say on that?

AirMotion Big Smart Fans are purposely designed to be 9 ft, 12 ft, and 15 ft in diameter with a low profile design. Their innovative sizes do not hinder the most common lighting and fire suppression setups to eliminate the counter-productive strobe effect created by the big fan blades spinning underneath lights, and avoid any issues with the concerned fire marshals and/or insurance underwriters; while their low profile design helps them fit in any applications including lower roof facility areas as well as above cranes and other areas where space is tight. Besides, it doesn't need to be so big if it smart. A 15 ft AirMotion Big Smart Fan is designed and capable to meet all your needs better than the old generation 24 ft HVLS fans. We move lots of air with our fans. Thanks to our unique VPT™ (Variable Pitch Technology), they don't necessarily need to be so big to effectively harness the laws of physics to create comfortable and productive facility environments while saving lots of energy.


Why AirMotion Big Smart Fans are called 'A Fan For All Seasons'?

AirMotion Big Smart Fans keep you cool in summertime (by creating a pleasing, non-disruptive breeze as can be felt by the seaside) and warm in winter (by eliminating stratification of heat/circulating wasted heat), since you can use them in both warmer or colder months to remain comfortable they are called 'A fan for all seasons'.


Can I run AirMotion Big Smart Fans in reverse?

No. AirMotion Big Smart Fans are not designed to be reversed, but using our Variable Pitch Technology (VPT™) you can set the blade pitch angles in reverse to get the air movement effect as desired. As folks in the US Navy told us 'You cannot fly a plane backward'. Unlike other blades with airfoil shapes taken from sailplanes or automobile spoilers designed to go in one direction, we have engineered our Rotatair™ blades to be symmetrical for 100% effectiveness in moving air up or down.


Which power source is required for the fan?

The standard power input is 120V but AirMotion Big Smart Fans are designed to work with all power sources.


How much space is required above the fan?

We have made them low profile - requiring at least a foot less mounting space than what we were used to. The fan unit is approximately 2 feet in height, from blade level to top of cover, which allows for mounting in tighter spaces. Though not a specific limitation as they can operate with minimal clearance, ideally having 5 feet or more above the blades allows for optimal air movement.


How much clearance is needed around the fan?

We recommend at least 3 feet of clearance above and below blade tips, and at least one foot of clearance to the sides of blade tips.


What is the recommended installation structure and height above the floor for the fan?

Designed for easy and low cost installation with simple mounting hardware, they can be installed in mostly any structure, as long as the blades are at least 10 feet above the floor. Ideal height is generally 15 feet or more, and we are unaware of any height limitations.


How much area can they cover?

For typical cooling objectives we recommend one fan for up to 10,000 sq ft or more; and for heat-destratification and general air mixing we recommend one fan for up to 20,000 sq ft or more as desired.


How much does the fan weigh?

The 15 feet AirMotion Big Smart Fans weigh about 230 lbs. including the control unit and mounting hardware.


What kind of maintenance is recommended for AirMotion HVLS fans?

Maintenance is typically limited to periodic cleaning/dusting of the composite blades (with our VPT™ and Rotatair™ Composite blades, dust is less likely to settle) and inspection of components and built-in safety features.


How long do they last?

AirMotion Big Smart Fans are built to last for a long trouble-free life. We use the best-engineered materials, and our engineering design expertise avoided unnecessary weak spots and high-torque wear and tear. They come with a lifetime warranty on blades and hubs, and multi-year warranty on all other components.


How can I buy AirMotion Next Generation HVLS fan?

AirMotion Next Generation HVLS fans are sold directly by AirMotion Sciences as well as through its authorized dealers and distributors. Please contact us for detail.


Thank you.

HOME ▪ AirMotion News ▪  Downloads ▪ Contact AirMotion

AirMotion Sciences, Inc. ▪ T 508-429-4411 T/F 508-653-3500


  The Science AirMotion Next Generation HVLS Fans Applications About AirMotion
   > Energy Efficiency  > The Smartest Features  > Distribution Center  > Our Mission
   > Energy Savings  > Benefits  > Manufacturing Facilities  > Our Team
   > Application of Physics  > Performance  > Commercial Facilities  > Sales & Support
 > Specifications  > Agricultural Operations  > Contact AirMotion
 > Why We Build Them

© 2007 - 2014 AirMotion Sciences, Inc. All Rights Reserved. SITE MAP ▪ DISCLAIMER ▪ PRIVACY POLICY