At the heart of every successful in-flight catering service lies a well-equipped kitchen, where culinary excellence meets stringent safety standards. Royal Blue Executive Services, renowned for its VIP, private, and commercial in-flight catering services across 24 airports in the United Kingdom, recently installed a new food production facility at its site at Stansted Airport. Our expertise was called upon to design, manufacture and install a state of the art extraction system that would comply with building regulations and ensure a fresh, clean, working environment for Royal Blue’s staff.

For us, the journey began with the challenge of how to extract a significant volume of air whilst maintaining an 85% replacement rate and minimising the loss of functional space within the building. Calling on the many of years of experience accumulated by our team, we designed a system that leverages energy-efficient, inverter-driven Helios fan units with powerful backward curved centrifugal impellers to deliver maximum performance within the constraints of what needed to be a very compact footprint. To complete the project in line with the detailed brief, we installed a user-friendly interface, in this instance using a Catersense gas interlock and fan control panel from Trent Controls.

The installed system goes beyond compliance, actively enhancing air quality and safety within the kitchen environment. By meticulously adhering to building regulations and DW 172:2018 standards, the system maintains negative pressure and ensures a comfortable air change rate for kitchen staff. A sophisticated gas interlock system, equipped with CO2 monitoring capabilities, provides continuous surveillance: should the working environment degrade, the control system automatically ramps up the fan performance, guaranteeing optimal conditions at all times. One of the standout features of the ventilation system is the custom-fabricated canopy which incorporates a perimeter capture and containment curtain. This innovative design facilitates the entrapment of any smoke, heat, and steam generated whilst cooking is taking place, further assisting operational efficiency.  

Looking beyond functionality, the system also prioritises energy efficiency and sustainability. With an IE3 motor complying with international efficiency standards and a backward-curved energy-efficient impeller, the system reduces both energy consumption and noise emissions, in line with Royal Blue’s environmental goals. 

Throughout the project, collaboration and communication between ourselves, our kitchen design partner, and Royal Blue were paramount. Through this, and meticulous attention to detail, we ensured that the installation process went as smoothly as possible whilst ensuring the system met all regulatory considerations including RAMS and DW172, as well as all Health and Safety workplace regulations. 

The impact of the ventilation system on Royal Blue's catering operations has been significant. By providing a comfortable working environment for team members, the system not only upholds the very best safety standards but also helps to boost productivity and staff morale. 

The finished project is an excellent example of REAL’s expertise in the design and installation of commercial ventilation solutions. Unlike projects driven purely by specification, this installation was designed, installed, and commissioned from the ground up, demonstrating our commitment to industry best practices and regulations.