The Client –
Leading manufacturer of nutritional products
The Challenge –
System upgrade whilst ensuring continuity of production
The Solution –
Aqua Pro chillers with short term chiller hire package
For a manufacturing client, replacing their aging chiller system was not just a chance to futureproof their production expansion plans, but also an opportunity to make efficiency gains by using the latest in process chiller technology.
Situation
The client specialises in producing a range of nutritional products, for leading brands, both in the UK and overseas. They manufacture infant formula, including an organic range, as well as meal replacement drinks. The industry is highly regulated and works to the highest food quality standards for nutritional requirements.
The existing process cooling system consisted of old chiller units, nearing the end of their lifespan. But rather than replacing like for like, our client wanted to ensure their new system would have additional capacity built in for when they increased production to meet growing demand.
Cooling is required at different points throughout their production process, especially at the pasteurisation stage. For example, when manufacturing organic infant formula, milk from organic farms is blended with a range of plant-based ingredients in large stainless-steel vats, forming a liquid mix.
The mix is pasteurised via a controlled heating and cooling process, which kills any potentially harmful microorganisms while preserving the product’s nutritional qualities. It’s also homogenised to achieve the right consistency and texture. Finally, the product is spray dried to a powder which can be reconstituted as needed, or it’s packaged into a ready to use convenience product.
Solution
Aqua designed, supplied and installed a complete chiller-based system, including a temporary hire solution:
- Short term chiller rental package
- 3 x 480kW Aqua Pro chillers
- Pipework
- Cranage into position
- Control panels
- Electrical works
- Full installation and commissioning
- Full 3-year service & maintenance plan
- Extended 3-year warranty, as standard
The factory work to a busy and demanding production schedule, meaning any downtime is lost revenue and commercially damaging to the business. By providing chillers and ancillaries from our hire fleet, continuous cooling was available when the fixed equipment wasn’t able to run. This mitigated risk and ensured production targets and deadlines were met at all times.
In addition, by upgrading to the Aqua Pro chiller units, the client benefits from much higher operational efficiencies which will save energy, reducing operational costs and carbon emissions. Aqua Pro chillers are specifically engineered for industrial and process applications, with a unique, cleanable evaporator that has large water pathways and energy efficient electronic expansion valves.
Results
“The success of this project is testament to how well our different internal teams supported the client from beginning to end” explains Regional Sales Manager, Mark Whittaker.
“By involving our hire division, we were able to assure continuity of production, which was crucial to the client. Everyone worked closely together, from our in-house system designers right through to the project and installation teams.
“I’m often asked what makes Aqua different, and I think one of the fundamentals is how sales, hire and service complement each other in achieving the absolute best outcome for the customer.
“We’re already collaborating with the client on the next stage of their expansion plans and I’m looking forward to what more we can achieve in the months and years ahead.”
If you’re looking for support with a process cooling application, give the team a call today on 0333 004 4433.
