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Bespoke water management solutions

11 May 2020

The continued growth of soft drinks manufacturer, Britvic, required the company to revaluate the water supply to its local factory in Rugby. It opted for an off-site build booster set in a mobile kiosk to ensure minimal disruption and no loss of production during installation. 

Britvic wanted to increase water storage capacity on site, meaning that during periods of high demand, the company would still be able to meet customers’ production expectations without having a negative effect on the local community. 

The was looking for a solution which would deliver the correct varying amounts of water, at the right pressure, and which would also contribute to reducing energy costs and the carbon output for the site. Remote access was also requested for monitoring, so trends would help with the continued optimisation of the system. 

Following initial meetings with Grundfos Pumps the concept and design of the kiosk was agreed. Britvic was looking for a kiosk with a high efficiency 5 x Grundfos booster set, using its multistage CR XL pumps. Also included in the package would be a dosing and disinfection system that would automatically clean any one of the water holding tanks, while leaving at least one in operation and working. This fully automated system would clean itself and conduct a full sterile check before going back in operation, without stopping the main water supply to the factory – resulting in continuous operation and manufacturing.  The system was also designed with future expansion in mind, with the ability to deliver over 400m3/hr.

Grundfos constructed and tested the full pump and disinfection package with full PLC control before mounting it into a mobile, weatherproof kiosk. Full operation and FAT tests were conducted before shipping to the Britvic site.

Installation time
The bespoke kiosk was then shipped to the Britvic site and was craned into position. Installation time, costs and risks were minimised because the packaged plant was already piped, wired, tested and pre-commissioned. Preparation at Britvic’s site was done separately, and in advance. 

The new pumping system is now in operation at the Rugby plant, helping Britvic to meet its own strict energy targets, in line with its strategy of reducing energy consumption, improving efficiency and process optimisation across its global business. The packaged booster set solution has resulted in a reduction in energy costs of 45%, which translates into cost savings of around £60,000 per year for Britvic.

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