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Pump system upgrade helps meet increased demand

27 February 2023

A pump system upgrade has helped a UK soft drinks manufacturer increase production and achieve impressive energy savings.

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Faced with an increase in demand for soft drinks and high energy consumption for moving the water required for their soft drink production, Britvic turned to Grundfos to look at options to increase production and reduce energy consumption across their plant in Rugby, United Kingdom.

Britvic was looking to support its sustainability agenda focusing on its ‘Healthier People, Healthier Planet’ strategy, which integrates the UN Sustainable Development Goals. 

It was important to Britvic to select a supplier that can support its ambition. Grundfos, with its own ambition of contributing to UN’s Sustainable Development Goals SDG #6 Clean Water and Sanitation, and SDG #13 Climate Action, was therefore a good match.

To help achieve the twin goals of increasing production and reducing energy consumption, Grundfos supplied a full turnkey project consisting of four Grundfos Hydro MPC-E booster sets with Grundfos iSOLUTIONS. The booster sets were custom built for Duty/ Assist/Standby operation, delivering the optimal amount of chilled water to the facility’s production lines, to allow for the high-speed filling of cans. Each of the installed booster sets incorporated three Grundfos CR pumps with integrated speed control.

Grundfos booster sets are designed to use multiple pumps to maintain a constant delivery flow or pressure, at maximum energy efficiency. When demand increases or decreases the water supply remains consistent thanks to the use of the Grundfos CU352 controller that ensures the pump set operates at its best performance. 

This intelligent booster set adapts automatically to the varying demands of the site. The inline vertical multistage centrifugal (CR) pumps can be used in a wide range of applications and are designed of world-class efficiency and reliability - with millions of customisable solutions.

Eight weeks were set aside for design and build, including a limited 18-hour window for overnight installation and commissioning. The booster sets installed were connected to Britvic plc via the Grundfos Communication cards.

“Improving our cooling system means that the chilled beverage water supplied to production stays cooler, resulting in faster production and higher output. Specifically, we were looking at acquiring a pumping solution that helps us meet our sustainability goals by reducing wastewater and energy usage, resulting in a reduced carbon footprint and improved water efficiency,” explained Calvin Winch, Engineer, Operations Development Great Britain and Ireland, Britvic.

With the new booster sets and improved cooling system, Britvic has achieved the desired increase in production, helping meet increased demand and future-proofing the production line. As the beverage water is staying cooler and temperature control has improved, faster production with an increased output is now possible, as more cans can be filled.

This project also helps Britvic work towards its sustainability goals with total energy savings of £374,420 per year expected with the four new booster sets. The existing system consumed over 60 kW per set, and this is now reduced to less than 20 kW per system, with the future-proof flow included. The return on investment (ROI) is under one year. With full control over the system, Britvic now also experiences a reduction in wastewater because the optimal amount of water for cooling is being used.

“We have set ambitious sustainability goals for energy reduction, a lowered carbon footprint and water reduction in our beverage production. Grundfos installed an energy, water and cost saving solution with no production disruption through time sensitive overnight installation and commissioning. This solution future-proofs our business, meeting the increased production demand, and shows when you work closely with your supply partners, we are much more effective, efficient and stronger together,” concluded Winch.

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