Proof in the Pudding: £117k Electricity Savings for Dessert Maker

The investment has also reduced carbon emissions, safeguarded production capacity, and ensured compliance with air quality standards for food production.

A challenge to reliability

The manufacturer, best known for its custard and rice pudding products, had been relying on older compressors that were running continuously without backup. Any breakdown risked an immediate 30 per cent loss in production capacity, which would force the company to hire temporary rental compressors to keep pace with demand.

Compounding the issue, the site’s existing dryer was undersized, operating at only three-quarters of the required capacity. As a result, it only just met compliance with the necessary dew point levels, increasing the risk of moisture and bacterial contamination within the compressed air system. The dated pipework added further inefficiencies through leaks, while the overall installation was unable to meet the expanding production requirements of the site.

Identifying the right solution

Atlas Copco began by logging the plant’s compressed air usage during full operation. This audit revealed that larger capacity compressors were essential to reliably meet demand. An AIRScan diagnostic assessment was followed by a full Site Acceptance Test (SAT) conducted by an external independent consultancy after installation. This validated both the performance of the new system and its ability to deliver air purity to ISO 8573-1 Class 1:2:0 – meeting standards for particles, oil and water contamination.

The audit projected energy savings of £117,000 per year in electricity costs, with additional reductions from heat recovery systems bringing the payback period to just 3.5 years. The site also stood to save more than 1,300 tonnes of CO₂ annually.

New generation oil-free technology

To address the challenge, the dairy manufacturer invested in three Atlas Copco ZR 160 VSD+ FF compressors, each featuring an iMDG integrated rotary drum adsorption dryer. The ZR range is engineered for industries where air purity is critical, delivering 100 per cent oil-free compressed air and certified to ISO 8573-1 Class 0 – the highest standard of air quality.

Variable Speed Drive (VSD+) technology enables the compressors to automatically adjust motor speed in line with fluctuating demand, achieving energy savings of up to 35 per cent. Meanwhile, the iMDG dryers consistently provide a pressure dew point as low as -63°C, ensuring compliance with food industry requirements, and verified in real time via Atlas Copco’s SMARTLINK monitoring system.

The installation also incorporated an Optimizer 4.0 central management system to ensure the most efficient load-sharing between compressors, as well as a Gateway 4.0 system that connects directly with the customer’s Building Management System. This allows plant operators to monitor compressor performance remotely and align the facility with Industry 4.0 standards.

In addition, the ER650 stand-alone energy recovery unit supplied by Atlas Copco harnesses the heat generated during air compression to allow the customer to re-purpose the wasted heat into other processes such as boiler pre-feed and wash down water at up to 85°C, and other indirect heat source requirements, offsetting energy costs elsewhere in production.

Proven results

The impact of the upgrade has been immediate. The customer reports far greater confidence in air quality, with no risk of oil contamination in its dessert lines. Dew point levels are consistently maintained, eliminating the previous vulnerability caused by undersized drying equipment. Furthermore, they have improved production output.

From a business perspective, the efficiency gains have driven down operating costs, delivering projected annual savings in excess of £200,000 and reducing the site’s carbon footprint. The new installation also provides built-in redundancy, ensuring 24/7 compliant compressed air generation and eliminating any risk to production compressed air supply. 

Partnering for the future

Reflecting on the success of the project, John Brennand, National Oil Free Sales Manager at Atlas Copco, said: “Food and beverage producers need absolute confidence that their compressed air systems won’t compromise product quality. But there is a risk of product contamination with any oil injected compressor system. You won’t know there’s oil in your end product unless you have a genuine oil-free compressor. With the ZR range, this manufacturer has complete peace of mind about ensuring Class 0 oil content from the compressor, alongside significant savings in energy and emissions.”

By modernising its compressed air system with Atlas Copco’s oil-free technology, the dairy desserts maker has not only safeguarded production and compliance but also strengthened its sustainability performance. The investment provides a foundation for further growth while ensuring that the company’s much-loved desserts continue to meet the highest quality and safety standards.

Find out more about oil-free compressor technology by visiting: www.atlascopco.com