Popping Room Ventilation Upgrade for Lundberg Farms

Background

Lundberg Family Farms, based in Richvale, CA, is a leading supplier of rice and rice products. Family-owned since 1937, Lundberg is known for its commitment to sustainability, producing Regenerative Organic Certified and non-GMO rice.

Their facility includes a 14,000 sq ft rice popping room housing hundreds of automated machines that produce rice cakes- a key product line.

The Problem

Each popping machine reaches over 700°F, generating significant smoke, fumes, and heat. With so many machines in use, the room regularly filled with heat and smoke, causing frequent production interruptions. The existing ventilation system couldn’t adequately clear the air, making the workspace uncomfortable and inefficient.

Cooper Oates conducted an engineering study to assess heat and airflow dynamics, then provided several design options. The selected solution was simpler and more cost-effective than Lundberg’s original plan.

The Solution

Cooper Oates developed and implemented a plan to reduce smoke-related shutdowns, improve comfort for staff, and enhance overall ventilation. This involved replacing outdated supply and exhaust fans with new air handlers and exhaust systems designed for easier maintenance and greater efficiency.

Work Performed

Cooper Oates replaced the overhead supply fans with floor-mounted fresh air handlers. Air was rerouted to wall diffusers at floor level to deliver clean air directly into employees’ breathing zones. Previously, air was supplied 12 feet above the floor, which failed to mix effectively with the rising smoke.

The new handlers feature filters, accessible fans, and energy-efficient redundant fan arrays, with coils installed for future chilled water cooling. The exhaust system was also upgraded, increasing capacity by 87% without requiring structural changes. Restrictive ductwork was replaced, and the new fans were installed outside, allowing maintenance without entering food production areas.

Results Achieved

The upgrade improved air distribution effectiveness by 25%, per ASHRAE standards. Once the new system was activated, smoke at operator level quickly cleared- earning immediate positive feedback from staff.

The exhaust system increased the air change rate by over 80% with just a 70% increase in horsepower. Ventilation capacity nearly doubled, rising from 48,000 to 90,000 CFM. The system is now easy to service and can support chilled water cooling for better temperature control in warmer months.