Case study: cider maker compresses air costs
6 Jun 2016
Modern compressor installation delivers increased energy efficiency for UK cider manufacturer.
Thatchers has been producing cider at Myrtle Farm, North Somerset since 1904. Its products, which include a range of classic, premium and flavoured ciders, are sold throughout the UK, US and Australia.
In 2014 the company’s new packaging and warehouse project — the Jubilee Building — was opened by the Earl and Countess of Wessex.
The building, named in celebration of the Queen’s Diamond Jubilee, will allow Thatchers to double its fermentation process and increase production from 52 million litres of cider a year to over 100 million litres.
Royal operation
Thatchers operations director Neil Day says development of the Jubilee Building is a major step in the company’s growth targets.
Thatchers says the incorporation of sustainable features to limit the environmental impact was important in the design of the Jubilee Building.
The company also aims to reduce its reliance on non-renewable energy sources and introduce sustainable measures throughout the production process wherever possible.
The building consists of high performance insulation, natural ventilation for cooling, large windows for maximum natural light and a biomass boiler to provide heating.
“It has been important for us to work with companies who provide a first class service and help us achieve our goals,” Day says.
Direct Air & Pipework has been able to install a compressed air system which allows us to work towards our energy efficiency targets
Neil Day, operations manager at Thatchers
Compressors are a major part of the building’s operation.
To help achieve efficiency targets, Thatchers called on the services of compressors distributor Direct Air & Pipework, which supplies Boge technology.
Direct Air & Pipework was awarded a contract to supply a compressed air system for the Jubilee Building that would contain the entire kegging facility, additional bottling line and a new canning line to allow further growth into the supermarket sector.
“Direct Air & Pipework has been able to install a compressed air system which allows us to work towards our energy efficiency targets,” Day says.
Special design
The Boge SLF 51 air compressor and downstream equipment supplied to Thatchers are designed to handle the varying demands of the sites processes, Direct Air & Pipework says.
The compressor also has a specially-designed airend that provides high output volumes at low energy consumption allowing for reliable and energy efficient compressed air supply.
In addition, a tighter/ reduced system pressure virtually eliminates off load running, which in turn reduces start-up current peaks, that contributes to potential energy savings of up to 40%, Direct Air & Pipework adds.
“The Boge compressor and downstream equipment in the Jubilee Building are all very energy efficient and will allow Thatchers to produce compressed air economically from day one,” says Direct Air & Pipework general manager Tim McGill.
“We work with lots of companies in the food and beverage industry supplying, installing and servicing compressed air equipment and nitrogen generators. We are excited to be able to look after the compressed air for Thatchers Cider and help them with their expansion,” McGill adds.
