Small-Duct, Big Impact: Unico HVAC for Modular Manufacturing

In this episode, Offsite Dirt sits down with Francis Leisure of The Unico System to talk about something every modular manufacturer cares about but doesn’t always spotlight: HVAC design that saves labor, protects schedules, and delivers better comfort for the end user.

Why factory installation changes the mathUnico’s small-duct, high-velocity system is designed to be installed in the factory rather than pieced together on site. That shift matters. When the air handler and ductwork are integrated on the line, manufacturers reduce field coordination, limit inspection surprises, and give the GC a simpler closeout—often just a licensed contractor to make final connections. In markets like Colorado, some manufacturers are even selecting their own HVAC contractor, taking that burden off the GC entirely.

Comfort and efficiency, by designBeyond labor savings, Unico’s value shows up in the lived experience. The system delivers even air distribution and tighter control of temperature and humidity—key drivers of indoor air quality and comfort. The discreet outlets and small profiles mean the system blends into ceilings or other finishes instead of dictating the look of the space.

A quick case studyAt a Boulder-area plant, Unico supported the manufacturer’s kickoff program. After early learnings, two installers were able to complete a system in three days—a strong signal for factories looking to forecast labor and takt time with confidence.

Routing where big ducts can’tModular thrives on space discipline. Unico’s supply tubing is about 3 inches in diameter, which opens up routing options that traditional duct systems struggle with. In many builds, that means running between floors (e.g., between the first and second story) without carving big chases, and avoiding equipment in unconditioned attics unless the design calls for a conditioned space.

Humidity control for healthier homesFor humid climates, moisture management is non-negotiable. By design, Unico targets meaningful moisture removal to protect the building and improve comfort—an important benefit for homeowners in the South and other high-humidity regions.

Design services built for Modular - Unico offers a dedicated design workflow for modular projects. Share floor plans and constraints, and the team will run loads, select equipment, design the duct layout, and return packages in PDF, AutoCAD, Revit, or even 3D—tailored for factory production and site set. That offloads engineering steps many factories would otherwise outsource and shortens the path from concept to install.

Turnkey kitting with WESCOMaterial flow is everything in a factory. Unico’s partnership with WESCO means components can be stocked, kitted, and delivered to match production cadence, with ancillary parts included. The result is fewer purchase points, less friction on the line, and consistent kits ready when modules are.

A new revenue lever for factoriesBecause the system is compact and design-forward, manufacturers can offer meaningful upgrades—controls, thermostats, ventilation packages—creating a clear HVAC revenue path while improving the homeowner experience.

See it for yourselfUnico designs and manufactures in Arnold, Missouri, with in-house testing. Plants considering the system are invited to tour and see how the equipment is built and validated before it arrives at their line.

Bottom lineFor modular manufacturers aiming to reduce field risk, save labor, and deliver a better homeowner experience, small-duct, high-velocity HVAC is worth a hard look. With factory-ready design support, national kitting through WESCO, and quiet, efficient comfort in the finished home, The Unico System aligns with how modular builds—precise, repeatable, and focused on the end user.

Want details on modular design packages or a factory visit? Head to unicosystems.com and ask for the modular design team, or connect with your local Unico rep.

FAQ's

• How does factory installation of The Unico System change the financial and logistical math for modular manufacturers? It changes the math by reducing field coordination, limiting inspection surprises, and simplifying the GC's closeout, as the air handler and ductwork are integrated on the line instead of being pieced together on-site.
  

• What specific benefits does the small-duct, high-velocity design provide in terms of space and routing? The system uses 3-inch diameter supply tubing, which opens up routing options that traditional large-duct systems struggle with, allowing installation between floors and avoiding large chases.
  

• What primary comfort and efficiency advantages does The Unico System deliver to the end user? It delivers even air distribution, tighter control of temperature and humidity (important for moisture removal in high-humidity regions), and discreet outlets that blend into finishes.
  

• How does Unico simplify the engineering and procurement process for modular factories? Unico offers a dedicated design workflow to run loads and design the duct layout (offloading engineering), and partners with WESCO for turnkey kitting and delivery to match production cadence.
  

• What was the result of the case study at the Boulder-area plant regarding installation time? After early learning, two installers were able to complete an entire system in three days, providing a strong signal for factories looking to forecast labor and takt time with confidence.