When air compressors really cut the mustard!

26 February 2021

Condimentum’s new mustard mill and mint processing facility includes an innovative air compression system which removes any risk of lost production or product spoilage, while also optimising energy efficiency.

Clean, dry, and reliable compressed air was an essential ingredient for Condimentum’s state-of-the-art production facility that processes fresh, locally produced raw materials into food ingredients. The facility is one of only three worldwide that is capable of producing double superfine mustard flour, a key ingredient in Colman’s English Mustard.

Condimentum was created in 2018 through agreement with Unilever to replace their primary processing facilities in Norwich. Today, the company’s main customer is Unilever who use the ingredients in their mustard paste and mint sauce.

“The scope of the project was complex, requiring a new compressed air system, complete with the associated compressed air ring main as a complete turnkey solution,” explained Steve Holman from HPC, a supplier of compressed air systems. “We were able to help minimise overall plant noise levels, to create a better working environment, and have allowed for higher volumes of compressed air if required due to future expansion.”

The HPC compressed air system, which was specified for use in the facility, provides sustained delivery pressure to the factory processing equipment (7.5 bar at plant room exit) and the compressed air management and control system intelligently selects compressors to avoid pressure dips on start-up. There is also remote access and control.

“The performance of our compressed air system has exceeded our expectations,” said Graham Muff, site Engineer at Condimentum. “The system operates quietly and unobtrusively allowing us to concentrate on our business and the productivity of our various operations, while minimising product spoilage.”

HPC installed air cooled rotary screw compressors, each with a capacity of 4.06m³/min to provide a source of energy-efficient, quality compressed air that delivers the required volumes day in, day out, and around the clock if necessary.

The units are inter-linked via a communication cable and configured to work on a programmed duty / rotate cycle. The control system helps optimise energy efficiency –especially in partial load operation.

The installation also features refrigerant dryers which reduce the pressure dew point of the air to 3°C to remove any moisture and a 2,000 litre capacity galvanised steel vertical air receiver for compressed air storage. A point of use desiccant dryer further reduces the pressure dew point of the air to -40°C, a critical requirement for the system.