Custom vs Modular AHUs: Which One is Right for your Project?

When selecting an AHU, the choice for manufacturers often boils down to custom vs. modular. Obviously, each option offers distinct advantages and trade-offs. There are projects where modular in not even an option and others where it’s the obvious choice. Also, depending on your design/build philosophy, you may lean toward one approach or the other.

However, choosing the right AHU not only affects the efficiency of your HVAC system but also has far-reaching implications for energy consumption, operational flexibility, and both upfront and long-term costs. And let’s be honest it can also impact the timeline and profitability of a project Let’s dive into the key differences and help you determine which option—custom or modular—best aligns with your project needs.

What Are Custom AHUs?

Custom AHUs are built-to-order systems tailored to the unique specifications of a project. These units are ideal for specialized applications where the site requirements (size, placement, etc.) are out of the ordinary and precise control over air quality, humidity, and temperature is critical. Custom solutions are often used for Healthcare and Lifesciences projects, data centers, cleanroom manufacturing settings, etc.

Key Features of Custom AHUs

Tailored Design: Custom AHUs are designed to meet exact project specifications, ensuring they integrate seamlessly with the building’s architecture and operational needs.
Component Flexibility: From advanced filtration systems to unique casing materials, every aspect can be customized.
Size Versatility: Available in a range of sizes to suit complex installations.

Advantages

Complete Customization: Custom AHUs can be tailored for specialized environments such as healthcare facilities, research laboratories, and industrial plants.
Specialized Performance: They excel in environments that demand strict air quality control or unique temperature and humidity requirements.
Energy Efficiency: With precision engineering, custom AHUs can achieve superior energy performance.

Disadvantages

Higher Initial Costs: The bespoke nature of custom AHUs typical drives higher upfront investment.
Longer Lead Times: Designing and manufacturing a custom unit takes more time compared to pre-configured options.

What Are Modular AHUs?

Modular AHUs, on the other hand, are pre-configured, scalable systems designed for fast deployment and flexibility in standard applications. These units come in sections or modules that are easy to transport, assemble, and expand as needed.

Key Features of Modular AHUs

Pre-Configured Design: Built using standardized components, which makes them faster to deliver and install.
Scalability: Modular units can be expanded or reconfigured to accommodate changes in building needs.
Efficient for Standard Applications: Ideal for many commercial appliances, offices, and schools.

Advantages

Cost-Effective: Modular AHUs are typically less expensive upfront, benefiting from economies of scale. They let you pick from a playbook of modules developed for past projects.
Quick Installation: Their pre-engineered nature allows for faster deployment, minimizing downtime. Again, because you are working from a known playbook, the installation parameters and requirements are all familiar.
Low Maintenance: Standardized components simplify repairs and maintenance but reducing the amount of inventory you need to keep on hand and by enabling your maintenance team tp focus their expertise on a smaller universe of components and assemblies.

Disadvantages

Limited Customization: One size really does not fit all. And even a range of customization options may not be enough. Modular AHUs may simplyi not meet the needs of highly regulated or specialized environments.
Standardized Design: May not always produce optimal efficiency. Forcing an off-the-shelf solution on a project with unique architectural or operational requirements will produce a result. But it may not be the best result in terms efficiency, capability or maintainability.

Comparing Custom and Modular AHUs: Key Factors

When choosing between custom and modular AHUs, consider the following key factors:

Cost and Budget Considerations

Custom AHUs: These often involve a higher initial cost due to bespoke designs and specialized components. However, they may provide long-term cost savings in energy efficiency and reduced operational costs for tailored applications.
Modular AHUs: More budget-friendly upfront, modular systems benefit from mass production and are ideal for projects with tighter budgets or standard HVAC needs.

Flexibility and Scalability

Modular AHUs: Offer ease of expansion and reconfiguration, making them a great fit for buildings anticipating changes in occupancy or usage.
Custom AHUs: Provide unparalleled design flexibility but are challenging to alter once installed.

Energy Efficiency

Both modular and custom AHUs can incorporate energy-efficient features like heat recovery systems and high-efficiency motors. However:
- Custom AHUs: Have the edge in specialized settings where energy efficiency can be maximized through tailored design.
- Modular AHUs: Still offer strong performance but may not reach the same level of optimization in unique environments.

Maintenance and Accessibility

Modular AHUs: Require less maintenance due to standardized components, making repairs and replacements straightforward.
Custom AHUs: May demand more specialized servicing, especially for non-standard parts or configurations.

When to Choose Each Option

Ideal Scenarios for Custom AHUs

Healthcare Facilities: Hospitals and clinics that require stringent air quality standards and infection control measures.
Research Labs: Environments that demand precise temperature and humidity regulation.
Industrial Applications: Facilities with unique operational needs, such as high-humidity manufacturing processes.

Best Applications for Modular AHUs

Commercial Buildings: Office spaces, retail stores, and schools where standard HVAC systems suffice.
Projects with Tight Timelines: Modular AHUs can be installed quickly, minimizing project delays.
Scalable Environments: Buildings expected to expand or change use over time.

For more interesting reading on modular vs. custom AHUs you can vist Kinetix Air users Coward Environmental’s article on the topic here. There’s aslo an interesting articl eon the subject on the Consulting Specifying Engineer website here. And you’ll find another take onthe subject on the site of Italian manufacturer Salda here.

Making the Right Choice

The decision between custom and modular AHUs boils down to your project’s unique needs and prioritiesand the way you approach the manufacturing process:

Choose Custom AHUs: If the project you are submitting on requires highly specialized air handling capabilities or operates under strict regulatory standards, the investment in a custom AHU will pay off in tailored performance and energy efficiency.
Opt for Modular AHUs: If cost, speed of installation, and scalability are key factors, modular AHUs provide a practical, efficient solution for standard applications.

For projects requiring the best of both worlds, consider Kinetix Air, which offers innovative solutions to blend the flexibility of custom designs with the efficiency of modular systems.

Kinetix Can Help You Accelerate AHU Design – Come Meet Us at AHR

Kinetix Air’s next-generation custom AHU selection tool helps you jump-start the design process and accelerate selection to help meet new demand. It also automates costing and validating, allowing you to respond to RFPs 90% faster and iterate designs on the fly. To speak with one of our experts about how Kinetix Air can help your business, click here to set up a call.

If you want the whole story on exactly how Kinetix Air can help give your SAEs superpowers, help you get selected as Basis of Design and raise your win rate, just click here.

Come meet us at AHR 2025 (booth 8575) from Feb 10-12 in Orlando at the Orange County Convention Centre in Orlando to experience the power of next-gen selection software to improve your bottom line.

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