This website uses cookies primarily for visitor analytics. Certain pages will ask you to fill in contact details to receive additional information. On these pages you have the option of having the site log your details for future visits. Indicating you want the site to remember your details will place a cookie on your device. To view our full cookie policy, please click here. You can also view it at any time by going to our Contact Us page.

Spirax Sarco steam system audit helps Dairy Crest

23 March 2010

Dairy Crest cut gas consumption at its Kirkby factory by 18%, thanks to a combination of energy saving measures, including steam system improvements recommended by Spirax Sarco

Steam system optimisation played a major role in achieving the overall savings, leading to an extremely rapid payback for Spirax Sarco’s audit. “In terms of payback we’re talking months not years,” says Dairy Crest Engineering Manager Gordon Davies.

“It was also useful to bring in Spirax Sarco to release our engineers who are mainly tasked with core activities like keeping the production lines running,” he explains. “In our busy manufacturing environment, some of the steam system jobs are pretty low on our day-to-day priority list so we decided to ask Spirax Sarco to do a full audit. We worked in partnership with them on the recommendations and together we met our stretched energy targets for the past two years.”

One of the big improvements was raising the temperature in the boiler feed tank, from between 79 and 82oC, to 96oC. As a rule of thumb, increasing the temperature of the feed to a boiler by 6oC reduces the boiler’s energy consumption by 1%, so this alone will have yielded savings of at least 2%.

Condensate recovery was another area that produced big results, raising the proportion of hot, treated water recycled back to the boiler from 76% to between 94 and 95%.

In addition, the steam system audit highlighted a variety of other energy saving measures, such as repairing and installing insulation, improving the blow down control on the boiler and repairing or replacing any malfunctioning steam traps. The Spirax Sarco engineers compiled an asset list of all steam traps around the site and Dairy Crest has now engaged Spirax Sarco to carry out an annual inspection and service across the entire population.

“It’s been a very good relationship and long may it continue,” says Mr. Davies. “Since the initial savings we have seen another 8% energy savings for 2009. This was helped by the annual Spirax Sarco steam survey, which identifies potential problems and reduces slippage with regards to energy savings.”

Dairy Crest’s Kirkby site in Liverpool manufactures well-known branded spreads, such as Utterly Butterly, Clover and Vitalite.

Contact Details and Archive...

Print this page | E-mail this page


Article image New investment for plant-based foods company Alpro

In March 2015, Alpro officially opened its newly extended production site, enabling them to double their capacity in their UK drinks facility. Food Processing took a look around the extended site.Full Story...

Article image Cheese packing factory closure will damage Wrexham economy, warns Unite

The closure of First Milk’s Maelor cheese packing site near Wrexham could damage the local economy and starve it of much needed jobs warned Britain’s largest union Unite, today.Full Story...

Dairy Crest talks apprenticeships at Appetite for Engineering

Food watchdog clamps down on milk powder manufacturers

Moody Systems to distribute Stoelting cheese making equipment


Article image Moody Systems to distribute Stoelting cheese making equipment

Moody Systems Ltd and RELCO, LLC are delighted to announce that they have signed a sole distribution agreement for Stoelting cheese making equipment that is designed and manufactured by RELCO, LLC of Willmar, Minnesota.Full Story...

Article image Heat recovery helps dairy farm reduce energy costs

A UK dairy farm was interested to learn if they were missing out on any potential energy and cost savings. The farm currently processes a large amount of milk which produces a considerable amount of heat. The farm also uses heated water for washing and sanitising equipment which was heated separately. ICS Temperature Control arranged a site visit to carry out an energy analysis.Full Story...

Made in Dorset to satisfy tropical taste buds


Article image Artificial intelligence in the food industry

Artificial intelligence (AI) has been heralded as the next best thing since sliced bread. But what might it really mean for the food industry and what are the implications? Stephanie Duvault-Alexandre explains. Full Story...

Article image Reduce, reuse, recover

Taking simple steps to reduce water consumption or access wastewater treatment technology can help change the way this valuable resource in managed, says Simon EmmsFull Story...

Added value: the best way to deliver ROI

Food Processing Awards 2018: Rewarding excellence and innovation in food engineering

A recipe for continuous improvement success