FOOD MANUFACTURING

Cranswick Foods Boosts Efficiency with Centralised Compressed Air

PROJECT REPORT

Improved efficiency and reliability at Cranswick Foods

Improved efficiency and reliability at Cranswick Cranswick Foods has transformed its compressed air supply with a new centralised system from BOGE. Three compact 55 kW compressors, a compressed air dryer and a new EasiFit distribution system replaced 10 individual compressors located throughout the Hull production facility.

The new installation has improved air quality, eliminated production downtime caused by low air pressure and provided additional capacity to support future growth.

A growing demand for compressed air

Cranswick Foods produces sliced and cooked meat products for food retailers and food service companies. Compressed air is used extensively throughout its Hull facility, supporting everything from control valves on cooking equipment to thermoforming machinery and end-of-line production equipment.

As the site expanded, its demand for compressed air continued to grow. Additional compressors were installed whenever more capacity was required, eventually resulting in 10 individual compressors positioned around the facility.

This piecemeal arrangement became increasingly difficult to manage. The existing system frequently struggled during periods of peak demand, while the distribution network meant that air supply was inconsistent across different areas of the plant.

BOGE compressed air system installed at Cranswick Foods

The need for a more reliable system

The addition of two new thermoforming lines pushed the existing compressed air system beyond its available capacity. As the machinery was sensitive to minimum air pressure, fluctuations in supply created a serious risk of production disruption.

Air quality was also causing problems. Water entering the distribution system led to frequent control-valve failures and production line shutdowns, sometimes occurring almost every week.

Following an analysis of the site’s compressed air usage, Cranswick began looking for a centralised, energy-efficient system with improved air treatment and sufficient standby capacity. BOGE was approached following a recommendation from another company within the Cranswick group.

Three BOGE compressors installed in the plant room at Cranswick Foods in Hull.

A centralised BOGE solution

At the heart of the new system are three 55 kW BOGE compressors installed together in a dedicated plant room. Two compressors operate at fixed speed, while the third variable-speed unit acts as the duty compressor and adjusts its output to match changing air demand.

The three-machine system replaced the 10 compressors previously located throughout the production facility. It also included a compressed air dryer to improve air quality and protect sensitive production equipment.

The plant can now operate using the two fixed-speed compressors while retaining approximately 25% additional capacity. This provides greater system resilience and gives Cranswick the potential to expand production by up to 40% in the future.

A more efficient distribution system

BOGE also installed a new compressed air distribution network using the EasiFit pipework system.

The lightweight 63 mm aluminium pipework uses push-fit connections, removing the need for welding. Its flexible design also makes it easier to adapt the system or add additional air drops as production requirements change.

This was particularly beneficial because much of the distribution system is installed within a difficult-to-access roof void. The new system was installed alongside the original pipework, allowing the final changeover to be completed during a single weekend.

BOGE compressed air system installed in the plant room at Cranswick Foods.

Reliable air for uninterrupted production

Since the installation, the new compressed air system has resolved the air-related issues experienced across the production facility.

Cranswick now benefits from a more dependable air supply, improved air quality and no production downtime caused by low air pressure. The centralised installation also fits neatly within the plant room and provides sufficient capacity for future expansion.

As John Milner, Engineering Manager at Cranswick Foods, explained:

“It’s done exactly what we wanted. We have no downtime caused by low air pressure, the air quality is much better, and it all fits in the plant room. The system just runs, and we don’t think about it, which really says it all.”

In a nutshell

Project information

The challenge

Continued site expansion had resulted in 10 individual compressors operating throughout the facility. The system struggled to meet peak demand, while poor air quality caused control-valve failures and production shutdowns on an almost weekly basis.

The BOGE solution

BOGE installed three centralised 55 kW compressors, including two fixed-speed machines and one variable-speed duty compressor. The installation also included a compressed air dryer and a new 63 mm EasiFit aluminium distribution system

The result

The new system has eliminated downtime caused by low air pressure, improved compressed air quality and provided approximately 25% spare capacity. It also gives Cranswick the opportunity to expand production by up to 40% in the future.

AT A GLANCE

Products in use

BOGE oelgeschmierter Schraubenkompressor S-3 Baureihe von 22 bis 75 kW

2 × SLF75-3 Screw Compressors

BOGE Druckluftbehälter zur Speicherung von Druckluft stehend verzinkt und liegend blau

3000 Litre Air Receiver

CUSTOMER

Cranswick Foods

Cranswick Foods, based in Hull, produces sliced and cooked meats for food retailers and food service companies. To improve reliability and efficiency across its production facility, the company upgraded to a new centralised compressed air system from BOGE.

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