Tag Archives: Booyco Engineering

CUTTING CORNERS ON HVAC SPECS COULD LEAVE OPERATORS IN THE HEAT, WARNS BOOYCO ENGINEERING

As surface mining and quarrying operations grapple with rising ambient temperatures, the way HVAC systems are specified for mobile equipment is coming under increasing scrutiny. Booyco Engineering, a specialist Original Equipment Manufacturer (OEM) of HVAC systems with over 40 years of experience in these demanding sectors, is sounding the alarm on the risks of relying solely on kilowatt ratings when selecting HVAC solutions.

Brenton Spies, Managing Director at Booyco Engineering, highlights a growing trend where specifiers and procurement departments are using only an HVAC system’s kW rating as a benchmark for selection. While this may seem like a straightforward approach, it is leading to complications on site often only becoming apparent once the equipment is installed and in full operation on the mobile mining machines.

“Not all HVAC systems  with the same kilowatt rating are created equal,” says Spies. “We are encountering cases where a unit is rejected for being ‘too expensive’ compared to other products with the same kW rating – only for the customer to discover later that the chosen system cannot cope with the site’s actual ambient conditions.”

The underlying issue, he explains, is that many buyers overlook critical international standards – specifically the ISO 5151 classification – which define the temperature classes to which HVAC systems are engineered. Known in industry as T1 and T3, these classifications set clear parameters for how equipment is expected to perform under different thermal conditions.

“These standards exist to guide the design, testing and validation of systems for specific environments,” Spies explains. “The materials, cooling capacities and componentry of a T3-class HVAC system, for example, are engineered to handle far harsher conditions than those of a T1-class system. This makes a significant difference in high temperature mining environments, where system failure is not just inconvenient but can compromise safety and productivity.”

“Our air conditioning systems are ISO 5151 T3-rated, meaning they are designed to operate in ambient temperatures of at least 46°C unlike many competitor systems, which are ISO 5151 T1-rated for just 35°C ambient temperatures,” says Spies. “This higher rating ensures our products maintain the specified performance in extremely demanding environments. A system designed for T1 will simply just not perform in T3 conditions, leaving the operator exposed to hazardous conditions.”

Spies emphasises that cutting costs at the procurement stage by opting for a cheaper system based on kW rating alone can end up costing operators far more in the long run. Unsuitable HVAC systems not only underperform in extreme conditions, but they are also more likely to suffer premature wear and require frequent maintenance or replacement.

He urges those responsible for specifying HVAC systems – particularly for mobile mining and earthmoving equipment – to consider environmental conditions and the applicable temperature classes as a fundamental part of the selection process. With climate conditions becoming more extreme, especially in remote and open-pit mining environments, ensuring that HVAC units are fit-for-purpose is more critical than ever.

Booyco Engineering continues to work closely with OEMs and end-users alike, applying its decades of expertise to ensure every HVAC system it supplies meets the rigorous demands of the application – not just in theory, but in real-world conditions.

BOOYCO ANTI-IDLE APU SLASHES FUEL COSTS AND CARBON EMISSIONS FOR MINES AND QUARRIES

Surface mining and quarrying operations are under increasing pressure to reduce costs and operate more sustainably with calls to reduce carbon footprints becoming more pressing. This is where Booyco Engineering’s Anti Idle Auxiliary Power Unit (APU), developed specifically for mobile mining equipment, is already proving to be a highly effective solution – dramatically reducing fuel consumption, lowering carbon emissions and delivering real financial returns.

In operations where diesel is one of the largest cost drivers, the numbers tell a compelling story. On average, articulated dump trucks (ADTs) idle for around 30% of the time, assuming productive time of 18 hours a day, which amounts to roughly 4.5 hours per day. During this idle time, the vehicle can burn between 30 and 50 litres of diesel per hour, simply to keep systems like the HVAC running and operators comfortable. That equates to hundreds of litres of diesel wasted per truck per week and thousands of litres across an entire fleet.

Booyco Engineering’s APU changes the equation. By providing an independent power source to drive the cab’s air conditioning and essential electronics, the Booyco APU allows operators to shut off the main engine entirely during idle periods. 

Grant Miller, Executive Director at Booyco Engineering, says the APU consumes as little as 1.5 litres of diesel per hour – compared to the 35 to 50 litres burned by a full-sized engine doing the same job. “It is a massive saving and when multiplied across a fleet the cost reduction becomes a gamechanger,” he says.

More than just a cost saving device, the Booyco APU is also helping mines meet their sustainability targets. By reducing unnecessary idling, operations can significantly reduce their carbon footprint – a critical step in meeting environmental, social and governance (ESG) goals. And with the South African Revenue Service (SARS) offering rebates under Section 12L for every litre of diesel saved, the financial incentive is even greater. The payback period on the Booyco APU is short, making it an easy investment decision for mining and quarrying operators looking for quick tangible returns.

Booyco Engineering, a specialist in HVAC systems for mobile mining equipment, designed the APU to integrate seamlessly with its robust 24 Volt air conditioning units which are already widely used in the field. The unit is T3-rated for use in ambient temperatures up to 46°C, making it ideal for hot climates across Africa. It is built for tough conditions and can be customised to meet specific customer requirements, ensuring flexibility and performance in even the most demanding environments.

Safety has not been compromised in the pursuit of efficiency. The Booyco APU continues to power critical systems such as proximity detection systems and communication equipment, ensuring that operational safety is maintained at all times, even when the main engine is shut off.

“This is not just a nice-to-have; it is a strategic advantage,” says Booyco Engineering Managing Director Brenton Spies. “Mining and quarrying companies that embrace this technology can dramatically cut one of their biggest operating costs, while also demonstrating real progress in reducing emissions and energy use.”

The Booyco Anti Idle APU is already gaining traction in the market with forward-thinking operations recognising its value as both a cost-reduction tool and a sustainability enabler. It represents a smart effective response to the challenges of modern mining – where every litre of diesel saved counts, both financially and environmentally.

CELEBRATING 40 YEARS OF EXCELLENCE IN SPECIALISED HVAC

Celebrating 40 years in business, Booyco Engineering has successfully evolved its specialised heating, ventilation and air conditioning (HVAC) offerings while remaining true to its commitment to quality and reliability, says Managing Director Brenton Spies.

“As a South African company, we are proud to have thrived through the many national and global shifts and challenges of the past four decades,” says Spies. “Our achievements speak to the value customers have gained from our engineering quality and innovation over the years.”

Initially focused on HVAC solutions for demanding military applications, Booyco Engineering soon diversified into the rail, mining and other industrial sectors – driven by the robustness of its products and strong manufacturing capability. In the rail sector, its specialised HVAC units commonly last up to 20 years, providing users with the lowest total cost of ownership while reducing the indirect costs of unplanned repairs and maintenance.

Grant Miller, Executive Director at Booyco Engineering, highlights that the company’s solutions are designed for applications where conventional HVAC systems simply cannot withstand the conditions. 

“As in military applications, the rail and mining sectors require solutions that can cope with high vibration levels, dust contamination and extreme temperature variations,” he explains. “Over the years, the strength of our solutions has been proven to customers who avoid frequent replacement or repair costs. This, combined with reduced downtime, ensures the lowest total cost of ownership.”

HVAC’s Growing Role in Workplace Safety

In recent decades, industries such as mining and earthmoving have seen a tightening of health and safety regulations. Employers are now required to ensure that mobile plant operators work in comfortable conditions, necessitating HVAC systems in sealed cabs.

“In many parts of Africa and beyond, hot daytime conditions make an HVAC system in mobile machinery indispensable for outdoor work,” says Spies. “When an HVAC system malfunctions, operations can come to a halt. The reliability of our solutions is not just a health issue – it’s a production issue. This is where customers see the real value of investing in quality and certainty.”

Another challenge arising from stricter health and safety standards is the common practice of operators idling their machines when stationary – such as when trucks wait to be loaded in an open pit – just to keep the HVAC running. This increases fuel costs and carbon emissions.

“A major advantage of being in business for so long is the depth of technical expertise and experience in our company,” says Miller. “We tackled this challenge on behalf of the sector by developing a dedicated Anti-Idle Auxiliary Power Unit (APU) that keeps the HVAC system running while the engine is switched off – significantly reducing fuel consumption and emissions.”

Driving Innovation and Expanding Reach

Booyco Engineering’s strong reputation has been built on its expertise in designing bespoke HVAC solutions for demanding applications. More recently, the company has also standardised many of its systems to enhance cost competitiveness and significantly reduce lead times.

“Our ability to deliver quickly is vital for Africa’s mining sector, where projects are often fast tracked and customers do not have the luxury of waiting for a bespoke design,” says Miller. “However, where a custom solution is required, our full design and engineering team ensures an optimal outcome including finite element analysis and ducting flow optimisation.”

Spies highlights that Booyco Engineering’s success is reflected not only in Africa but also in global markets with its HVAC units operating in Europe, North America and South America.

“Our recent focus on mining is opening doors in Asia and Australia as well, where many of our OEM customers are deploying their machines with our equipment,” he says. “Our value is especially evident in remote locations, where replacements and repairs are difficult and customers can rely on Booyco Engineering for a product that performs reliably under the harshest conditions.”

HIDDEN LINK BETWEEN HVAC PERFORMANCE AND HEAVY-DUTY EQUIPMENT UPTIME

In the demanding environments of mining and quarrying, equipment reliability is non-negotiable. Often overlooked, however, is the critical contribution that heating, ventilation and air conditioning (HVAC) systems make to both operator safety and the reliable performance of machinery.

Booyco Engineering, South Africa’s leading specialist in custom HVAC solutions for heavy-duty mobile equipment applications, highlights that poorly performing HVAC units can directly impact equipment uptime and operational efficiency. According to Brenton Spies, Managing Director, HVAC systems in mining vehicles and earthmoving equipment as well as specialised rail and military applications are more than just comfort systems – they are integral to productivity and safety.

“Mining operations often run in extreme heat, dust and humidity,” says Spies. “If an operator is working in a cab where the HVAC system is not functioning optimally, concentration levels can drop, fatigue sets in faster and safety risks increase.”

Additionally, electronics and controls inside the cab rely on stable environmental conditions and without efficient climate control these systems can fail or deliver unreliable performance.

Booyco Engineering has built a strong reputation as a trusted Original Equipment Manufacturer (OEM) for designing and manufacturing robust HVAC units locally, engineered to withstand the harsh conditions of African mines. 

“We design for vibration, dust ingress, extreme temperature variations and easy serviceability,” he says. “Our units are purpose-built for the realities of heavy industry such as mining and quarrying, with all components tested and verified to perform under load.”

A key differentiator, according to Spies, is the company’s focus on reliability and lifecycle cost. “Downtime caused by HVAC failure doesn’t just inconvenience the operator, it can halt production, impact fleet availability and lead to unplanned maintenance costs. Our systems are engineered to reduce these risks, providing dependable performance over extended operating periods.”

Booyco Engineering’s in-house design, engineering and manufacturing capability also allows for custom solutions tailored to specific vehicle types and operating conditions. “We work closely with OEMs and end-users to specify HVAC solutions that perfectly align with their operational requirements, whether it is open pit mining at higher altitudes or operations with severe air quality challenges,” Spies explains.

As mining and quarrying operations across Africa continue to push the boundaries of performance and safety, the role of reliable HVAC systems will only become more critical. Booyco Engineering’s focus remains on delivering well-engineered and locally manufactured solutions that support equipment reliability and operator wellbeing which according to Spies is a solid contribution that is vital to sustainable productive mining operations.

BOOYCO ENGINEERING AND COBRA TEAM UP IN SY-KLONE SOLUTION FOR AUSTRALIAN MINE

Meeting world class standards in air quality, South Africa-based Cobra Projects is producing 14 ventilated operator cabins for a Tier 1 mining company in Australia – fitted with Sy-Klone filtration systems supplied by local HVAC specialist Booyco Engineering. 

The cabins allow operators to remotely operate heavy mining equipment in their line of sight, providing a cool and dust-free environment to enhance their concentration and performance. Adhering to tight lead times, two of the units have already been shipped and the remainder will be on site in Australia in the last quarter of 2024. 

“One of the critical aspects of a sealed cab is allowing the entry and recirculation of fresh air, to provide a safe and conducive environment for the operator,” says Neal Forman, Business Development Manager at Cobra Projects. “We achieved this through our collaboration with Booyco Engineering who supplied the Sy-Klone fresh air pre-cleaner as well as the recirculation component and monitor.”

Sy-Klone’s patented RESPA® air quality products reduce respirable dust and debris, providing clean air to HVAC systems and keeping recycled air safe and breathable. The system also includes specialised filters for the recirculated air inside the cab. 

“In line with the ISO 23875 global standard for cab air quality, we also included Sy-Klone’s RESPA Advisor cab monitors from Booyco Engineering,” he says. “These monitors raise safety levels by ensuring the operator or supervisor is always kept informed on the pressure and quality of the air in the cab.”

If there is a build-up of unsafe levels of carbon dioxide in the cab, which can lead to operator fatigue and loss of alertness, the monitor can sound an alarm. It will also detect a loss of pressure, which can allow harmful respirable particulate to enter the cab.

Forman highlights that health regulations dealing with air quality in countries like Australia are becoming more stringent – making it essential that their specifications on this contract complied with ISO 23875. 

“Our business is really about continuous improvement, so we work with partners like Booyco Engineering to incorporate high value technologies like Sy-Klone’s air quality solutions,” he says. Cobra Projects specialises in custom-built, special-use vehicles for opencast and underground mining, to provide services such as lubrication systems and diesel and water transportation. Prior to this Australian contract, the company had designed and constructed a range of self-contained cabins for remote equipment operation on mines.

He notes that, while the ISO 23875 air quality standards is not yet a mandatory requirement on South African mines, it is likely that this step is only a matter of time – especially for the dusty conditions at coal mines. 

TRENDS IN HVAC SYSTEMS FOR MOBILE EQUIPMENT IN SURFACE MINING

The landscape of HVAC systems for mobile equipment in surface mining and quarrying sectors has evolved significantly over the past decade. The shift has been towards more robust systems capable of withstanding the harsh conditions typical of these operations. Brenton Spies, Managing Director of Booyco Engineering, says that trends in HVAC systems have focused on operator safety and comfort, system reliability and environmental considerations.

“Over recent years, there has been a pronounced focus on operator safety and comfort,” Spies says. “The classification of climate as a Class A hazard underscores the importance of providing operators with comfortable working conditions. Ensuring a safe and comfortable environment is not just about individual wellbeing but also about enhancing productivity.”

“Reliable and effective HVAC systems are crucial in maintaining a safe working environment around the clock, and Booyco HVAC solutions play a vital role in improving working conditions, whether in extreme heat or cold,” he says. By ensuring a comfortable working environment, HVAC systems help maintain cognitive awareness among operators, preventing accidents. 

Booyco HVAC systems assists in preventing serious medical conditions that could jeopardise an operator’s health and safety and by combining HVAC systems with air filtration systems mitigates the risk of respiratory illnesses by removing harmful gases and particles from the operator cab. Booyco HVAC systems are designed to integrate seamlessly with Sy-Klone air filters, enhancing air quality. Booyco Engineering is an authorised distributor of Sy-Klone air filters in southern Africa.

Spies explains that maintaining uptime of equipment on a surface mining site is critical for minimising operational costs, especially given the current pressure on commodity prices. “Good working conditions are integral to this. Operators have the right to stop working if the HVAC system in their cab becomes dysfunctional, potentially causing significant interruptions to mining operations. This, again, reinforces that reliable HVAC systems are essential to ensure continuous operation.”

Mining environments are inherently extreme, with operations often located in remote areas with severe weather conditions. Dusty operating environments are common, despite dust mitigation efforts. Booyco HVAC systems are engineered to withstand these harsh conditions, with attention to detail ensuring the systems can handle extreme vibrations when traversing rough terrain. Quality components are selected during the design phases to ensure reliable performance under these extreme conditions.

“Ongoing maintenance of HVAC systems is just as crucial as selecting the most appropriate system for an application to ensure reliability, and we offer maintenance contracts and Man on Site (MOS) options that facilitate preventative maintenance and ensure optimal uptime of our HVAC systems, ensuring maximum fleet uptime.” 

A notable trend in recent years is the move towards more environmentally friendly refrigerants. Supporting the sector’s commitment to reducing its carbon footprint, Booyco Engineering has developed a fully integrated HVAC anti-idle auxiliary power unit (APU). This innovative solution significantly reduces diesel consumption during operational idle times, leading to a reduction in operating costs.

“The evolution of HVAC systems for mobile equipment in surface mining reflects a comprehensive approach to tackling the industry’s unique challenges, and Booyco Engineering has been at the forefront of these developments with continued emphasis on robust design, operator safety and comfort, reliable performance and environmental responsibility,” Spies says. “By continuously innovating, we ensure that operators work in safe, comfortable environments, enhancing productivity and operational efficiency across the mining sector.” 

BOOYCO ENGINEERING SUPPORTS MINES’ ESG GOALS WITH DIESEL-SAVING INNOVATION

A truly groundbreaking diesel-saving innovation poised to revolutionise surface mining and quarrying operations was unveiled at Electra Mining Africa by Booyco Engineering. Recognising that diesel consumption is one of the highest operating costs in these sectors, Booyco Engineering has developed an anti-idle auxiliary Power Unit (APU) that when applied across operational fleets, particularly haul trucks, will result in significant cost savings and a reduction in carbon emissions.

The Booyco Engineering APU is designed to keep the HVAC system running inside an operator cab while the machine’s main diesel engine is turned off. This ensures operators remain cool and comfortable during idle periods, such as waiting for loading. By eliminating the need to use the main engine to power the HVAC system while idling, diesel costs are dramatically reduced.

Grant Miller, Executive Director at Booyco Engineering, says the company, a specialist in heating, ventilation and cooling equipment for mobile mining machinery, engineered the APU to drive in-cab air conditioners. “In the high ambient conditions prevalent on southern African mines, mining truck operators must often keep the main engine running to maintain a comfortable cab temperature while waiting to be loaded. While this is understandable in terms of maintaining a cool environment from both a safety and productivity perspective, this practice can consume between 30 and 50 litres of diesel per hour,” he explains.

Miller says that the Booyco Engineering APU addresses this inefficiency by allowing the main engine to be powered down during idle times. “And our APU consumes just 1.5 litres of diesel per hour while still keeping the cab cool and comfortable.”

Safety is not compromised with the introduction of the Booyco APU. The unit ensures that all essential systems, such as proximity detection systems and communication systems, remain powered and operational even when the main engine is off. This attention to safety, combined with enhanced efficiency and reduced operating costs, makes the APU an indispensable tool for modern mining operations.

Developed in response to the need for comfortable working conditions and reduced costs, the Booyco Engineering APU is particularly valuable in hot climates such as those found across the African region where daytime heat necessitates constant use of HVAC systems. It maintains comfort during unproductive periods, such as when haul trucks are waiting to be loaded by mining shovels or similar equipment. Beyond reducing diesel consumption, the APU also helps lower carbon footprints, enabling mines to progress toward their ESG goals.

Significantly, the cost of the APU is offset by its relatively short payback period, thanks to its low running costs.

The robust 24 Volt air conditioning system used in mining trucks and other equipment integrates seamlessly with the APU. The APU is T3-rated and suitable for operation in ambient temperatures up to 46 degrees Celsius.

Further, Miller explains, it can be configured to suit individual customer requirements

By significantly cutting diesel consumption and carbon emissions, the Booyco Engineering APU is a pivotal advancement for the mining industry, enabling operations to enhance efficiency, reduce operating costs and meet carbon emission targets while ensuring safety and comfort for operators.

UPTICK IN DEMAND FOR BOOYCO HVAC SYSTEMS BY SOUTH AFRICA’S OEM SECTOR

There has been a noticeable uptick in demand for the locally manufactured Booyco HVAC systems by South Africa’s Original Equipment Manufacturers (OEM). Brenton Spies, Managing Director of Booyco Engineering, says that the upswing is seen as a promising indicator of growth within the South African OEM landscape, highlighting a robust response to local manufacturing capabilities and innovation.

Booyco Engineering, known for its high quality locally engineered and manufactured HVAC solutions, has received an influx of orders from a range of local OEM facilities. Some of these facilities specialise in producing underground mining machinery such as Load-Haul-Dump (LHD) units and utility vehicles, while other manufacture surface mining equipment and construction machinery. 

Spies say that the growing demand for Booyco’s HVAC systems underscores their reputation as a reliable and purpose-built solution, capable of enduring the extreme conditions often found in Africa’s challenging environments.

“South Africa’s mining and construction sectors, in particular, are notorious for their demanding operational contexts, where equipment must withstand not only physical stresses but also extreme temperatures,” he says. “With summer temperatures frequently exceeding 34 degrees Celsius, the need for durable and efficient HVAC systems has never been more critical. By designing for T3 conditions of ambient temperatures up to +46 degrees Celsius, our offerings stand out in this regard, providing a range of standard HVAC systems alongside the ability to partner with OEMs for custom-designed solutions tailored to specific equipment requirements.”

A key differentiator for Booyco Engineering has been its commitment to local production underpinned by rigorous in-house testing. Each HVAC system is developed and tested under the harshest conditions to guarantee performance reliability in the field. This local manufacturing approach not only supports the South African economy but also ensures that products are ideally suited to local conditions.

Supporting these systems in the field, Booyco Engineering operates a team of skilled artisans as part of their field service crews. These professionals are essential for maintaining the high performance and reliability of Booyco HVAC systems in the field, with the company even offering man on-site contracts where necessary to provide continuous support.

Moreover, Spies says, Booyco Engineering is aggressively expanding its reach within Sub-Saharan Africa by appointing distributors and service providers. This strategy aims to provide localised support and service to customers across the region, further enhancing the accessibility and reliability of Booyco’s HVAC solutions.

“We believe the increased demand for Booyco Engineering’s HVAC systems from South Africa’s OEM sector is a testament to the company’s innovation, quality and commitment to supporting local industries,” Spies concludes.

ENGINE AIR FILTER PRE-CLEANERS SAVE COAL MINE ON FILTER COSTS, DOWNTIME

Heavy duty cooling and air conditioning specialist Booyco Engineering has installed the innovative Sy-Klone engine air filter pre-cleaners on two drill rigs at a South African coal mine, allowing the customer to save on the costs of both replacement air filters and operational downtime.

“In dusty mining conditions, engine air filters quickly clog and need replacing,” explains Gordon Postma, Sales Manager at Booyco Engineering. “On this coal mine, the drill rig filters were lasting only two or three days before they needed replacing; the customer really needed a more sustainable and cost effective solution.”

This was provided through the supply and installation of four Sy-Klone Series 9000 engine air filter pre-cleaners – two on each drill rig. This leading technology from the US has been proved over decades, and has been continuously refined and improved.

“The result is that these Sy-Klone engine air filter pre-cleaners can collect and expel 92 to 95% of the ambient dust before it even reaches the engine’s air filter,” says Postma. “The scientific design and robust manufacture of the pre-cleaners – using hard polymer plastics for strength – ensures they need little to no maintenance, and can withstand operating in harsh mining conditions.”

The operating principles of these air pre-cleaners make them remarkably effective, he says. Air enters the underside of the dome design through screened louvers. This prevents any large debris from entering the pre-cleaner which could cause restriction in airflow. Curved particle-accelerator blades push dirt against the sidewall, and strakes – or angled fins – along the interior surface move all heavier-than-air debris towards the ejection slot. This leaves the clean air to continue swirling to the centre of the dome and through to the engine air filter inlet pipe into the engine’s air filter housing through the filter and then into the engine.

“By installing the Sy-Klone engine air filter pre-cleaner, the mine can significantly extend the service life of its engine air filters,” emphasises Postma. “While the savings on the costs of these filters will be important, the real cost to the mine is in drill rig downtime while the filters are changed. The operation will now benefit from better efficiency and productivity due to less maintenance.”

He adds that, by keeping the engine’s air filter cleaner for longer, the pre-cleaner also enhances the performance and fuel efficiency of the engine – as there is less restriction of air moving into the combustion chambers.

“These various benefits add up to a comprehensive solution for the customer, with minimal technical intervention as the pre-cleaners can be readily sized and installed with little disruption to production,” he says.

As a relatively recent addition to Booyco Engineering’s market offering, the Sy-Klone distributorship shows considerable potential in South Africa’s mining sector, as well as in other applications where machinery must operate in high levels of dust. Postma says there is potential for more pre-cleaner installations by this coal mining customer, while a number of other expected installations will soon confirm the product’s efficacy under a range of local conditions.

LATEST SA-DESIGNED HVAC FOR MILITARY VEHICLE

South Africa-based Booyco Engineering has upgraded the heating, ventilation and air conditioning (HVAC) system for a customer’s 8×8 armoured personnel carrier.

With almost 40 years of experience in custom designed robust HVAC solutions for the defence sector, the latest prototype is the third iteration of a bespoke unit for this longstanding export customer. According to Grant Miller, Executive Director at Booyco Engineering, the key advances in the latest system have been its integrated electronic control system and the addition of heating functionality.

“This version of the unit allows the driver two-way engagement with HVAC related information on the vehicle’s touchscreen dashboard consol, rather than via a standalone control panel,” says Miller. Using a controller area network (CAN bus) enabled controller, the HVAC’s control system is now fully integrated into the vehicle’s control communication network. The unit makes use of a micro-processor controller that was locally developed specifically for HVAC applications in military vehicles. The addition of heating to the system means that the vehicle can now be deployed in areas with colder climates.

Designed and manufactured in South Africa, the HVAC system is fully rated to stringent military standards. These include environmental specification MIL-STD-810G, MIL-STD-461C and MIL-STD-464C specifications on electromagnetic conformance and interference, and MIL-STD-1472F on general human engineering design. It was supplied to the customer in mid-2023 and has undergone extensive field testing under demanding conditions.

Ross Macphail, Engineering Manager at Booyco Engineering, highlights that the customer is also developing a hybrid electric-drive version of the same vehicle – in which the batteries will also require cooling.

“They intend to use our HVAC system for their new hybrid vehicle, where our equipment will be cooling not just the internal crew space but the batteries as well,” says Macphail. The large traction motor batteries on electric vehicles need to be actively cooled during operation.

He points out that this system also makes use of brushless DC compressors as opposed to a traditional engine driven compressor, which allows the HVAC system to be run independently of the vehicle engine.

Booyco Engineering’s HVAC equipment is designed to perform reliably in the high levels of shock, vibration and dust encountered in military applications. It also limits electromagnetic interference (EMI), which is unwanted electrical noise radiated and conducted from the equipment during operation. This aspect is particularly important in a military context, where EMI can negatively affect communication and other electronic equipment in the vehicle.