Deli 24 strengthens food manufacturing reliability with Atlas Copco oil-free compressors

Its process applies intense pressure to packaged foods, delivering the same pathogen reduction as pasteurisation while preserving taste, colour and nutritional value. Within this environment, compressed air plays a vital supporting role, powering machinery and enabling processes such as air knives for drying packaging prior to date coding.

"Compressed air is an essential part of our whole process," said Paul Winter, director at Deli 24. "From conveyor systems to the operation of key machinery, it underpins a lot of what we do day to day. When you’re producing food for major retailers, everything must work exactly as it should."

A joined-up approach to system performance

Deli 24 had operated an oil-free compressor on site for more than 15 years, supported by a long-standing service relationship. As operational requirements evolved, however, the company took the opportunity to reassess its compressed air system more holistically.

Atlas Copco began with a full air audit, examining not just the compressor itself but the wider distribution network and how air was being used across the site. This identified inefficiencies including previously undetected air leaks, prompting upgrades to pipework and connections using more modern systems. A follow-up audit confirmed the improvements, ensuring that the compressed air being generated was now being used effectively across the process.

"It wasn’t just about replacing a machine," Winter explained. "It was about understanding what we had, how we were using it, and where improvements could be made. That gave us a much clearer picture of what the right solution looked like."

Building resilience into production

Alongside system optimisation, Deli 24 introduced a second ZT22 VSD oil-free rotary tooth compressor, creating a duty/standby arrangement to support production continuity. The new compressor sits alongside the existing ZT22 VSD unit, providing additional capacity while maintaining operational flexibility for future growth.

This configuration means that maintenance can now be carried out during normal working hours, without impacting production schedules. It also ensures that compressed air supply can be maintained even if one unit is offline.

"For us, the biggest benefit is peace of mind," Winter continued. "We’ve had a very reliable system over the years but having that additional compressor in place gives us confidence that we can keep running without interruption. That’s particularly important in a food environment like ours."

Supporting food safety and compliance

Given the nature of Deli 24’s operations, air quality is equally critical. Oil-free compressed air from Atlas Copco’s ZT rotary tooth compressors supports applications where there is potential contact with food products or packaging, helping to eliminate contamination risk and support compliance with food safety standards.

The company operates to strict retailer and certification requirements, with regular audits from both customers and regulatory bodies. Within this context, the reliability and quality of compressed air are closely linked to maintaining those standards.

"As we work with a wide range of food products, including ready-to-eat and baby food, maintaining a clean and controlled environment is essential," Winter adds. "That extends to utilities like compressed air, which form part of the overall process."

A turnkey installation

The project was delivered as a fully managed installation, covering planning, equipment positioning, pipework modifications and commissioning. Despite the constraints of an existing plant room, the system was reconfigured to accommodate both compressors side by side, alongside additional equipment including an air receiver to support system stability.

Installation was carried out in stages to minimise disruption, with work scheduled around production requirements. Once complete, the upgraded system was integrated seamlessly into operations.

"We wanted a turnkey solution, and that’s exactly what we got," said Winter. "From the initial discussions through to installation and commissioning, everything was handled as one joined-up process. That made a big difference for our engineering team."

Looking ahead

In addition to improving reliability, the system has been designed with future growth in mind, providing additional capacity as Deli 24 continues to expand its operations. The company is also exploring digital monitoring tools to provide greater visibility over performance and maintenance planning.

For Atlas Copco, the project highlights the importance of taking a system-level view of compressed air needs rather than focusing solely on equipment replacement.

"Understanding how compressed air is used across the site was key," stated Michelle Tripp, oil-free sales engineer at Atlas Copco. "The audit allowed us to identify inefficiencies, address them, and then specify a solution that supports both current operations and future plans. Alongside that, introducing a duty/standby arrangement gives Deli 24 the resilience and flexibility they were looking for."

For a business built on delivering safe, high-quality food at scale, that combination of performance and reassurance is critical. By strengthening its compressed air infrastructure, Deli 24 has created a more robust foundation for its HPP operations, ensuring that essential processes continue to run smoothly, day in and day out.

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