Case Study
Landmark Yoghurt Cooling Solution for Leading UK Dairy Manufacturer
Overview
Client: Yoghurt & Dairy Producer
Industry: Dairy
Project Overview: The project, set for completion in late 2024/early 2025, involves the installation of an advanced multi-cell cooling system at the manufacturer's flagship facility, developed in collaboration with Clauger to integrate rapid pallet Cooling Cells that optimise the cooling of dairy products with improved energy efficiency and precision, positioning the client as a leader in global dairy cooling innovation.
At Penmann, we are thrilled to announce the award of our largest-ever contract with one of the UK’s most prominent yoghurt and dairy producers. This new project, which underscores a 23-year-long relationship built on trust and innovation, marks a pivotal moment not only for Penmann but also for the UK dairy industry. The scale and scope of the project make it the largest of its kind in the UK, and possibly globally, setting new standards for industrial cooling solutions in the dairy sector.
Innovative Cooling Technology
The Cooling Cells being implemented as part of this project have been engineered to deliver substantial performance improvements in the cooling of palletised products. The technology has already proven its effectiveness in over 3,700 installations worldwide, making it a well-established solution for high-demand environments like dairy production. The key to the system’s success lies in its ability to form an airtight seal around each pallet, which prevents any air bypass and ensures maximum cooling efficiency. By eliminating the inefficiencies commonly associated with air leakage in traditional systems, the Cooling Cells enable yoghurt and other dairy products to be cooled to under 5°C in less than an hour, a crucial improvement for preserving the quality and shelf life of perishable goods. This rapid cooling process is not only beneficial for maintaining the integrity of the dairy products but also ensures that production timelines can be maintained or even shortened, improving overall operational efficiency.
Energy Efficiency and Cost Savings
One of the defining features of the Cooling Cell system is its remarkable energy efficiency. Traditional blast chilling systems are often energy-intensive, requiring substantial cooling power to achieve the necessary temperatures, particularly for high-volume production. However, the design of the Cooling Cells allows for far greater energy savings by using precise cooling control and efficient airflow management. By focusing the cooling directly on the product with minimal waste, the system reduces the overall energy load required to bring products down to the desired temperature. For the client, this translates into significant long-term cost savings, as the system requires less power to operate while still delivering faster, more reliable cooling results. Furthermore, by reducing the energy footprint of the cooling process, the system also contributes to the client’s broader sustainability goals, helping to reduce the environmental impact of their operations.
Overcoming Complex Challenges
The scale of this project presents several complex challenges, particularly in relation to the vast volume of yoghurt and other dairy products that need to be cooled efficiently and within tight production windows. The manufacturer’s flagship site is a high-output facility, meaning that any cooling system installed must be capable of handling a large throughput without causing bottlenecks or downtime in the production process. Penmann’s approach to overcoming these challenges involved a detailed analysis of the site’s operational needs, working closely with the client to ensure that the solution would not only meet current production demands but also be scalable for future growth. The Cooling Cells, with their modular design, provide the flexibility needed to accommodate any future increases in production capacity, ensuring that the system remains robust and adaptable in the years to come.
Additionally, the integration of Clauger’s technology with Penmann’s engineering expertise ensured that the system was designed to optimise the layout of the facility, making use of existing infrastructure while incorporating the latest advances in cooling technology. This allowed for a seamless implementation of the Cooling Cells without the need for extensive modifications to the site, thereby reducing installation time and minimising disruption to ongoing operations.
A Collaborative Achievement
This project represents a major milestone not only for Penmann but also for our long-standing relationship with the client. Over the past 23 years, we have worked closely with this leading dairy producer, providing them with innovative cooling solutions that have helped streamline their operations and improve product quality. The award of this contract, the largest of its kind, is a testament to the trust that has been built between our organisations, as well as to Penmann’s continued commitment to pushing the boundaries of what is possible in industrial cooling. The collaboration with Clauger, a global leader in refrigeration and cooling solutions, has also been key to the success of this project. Clauger’s patented Cooling Cells are at the heart of the system, offering an advanced and proven solution that perfectly complements Penmann’s expertise in delivering high-performance cooling systems to the UK dairy sector.
Conclusion and Future Impact
The successful implementation of this advanced cooling solution will have a transformative impact on the client’s flagship production site. By dramatically reducing cooling times and enhancing energy efficiency, the system will not only improve the overall productivity of the facility but also significantly reduce operational costs. In a sector where margins are often tight and the quality of perishable products is paramount, the ability to rapidly and effectively cool products will provide a major competitive advantage. The environmental benefits of the system, through its reduced energy consumption and lower carbon footprint, align with the client’s sustainability objectives, helping them to meet increasingly stringent environmental regulations and consumer expectations around sustainability.
As we move towards the completion of the project in 2024/2025, Penmann is proud to continue its leadership in the field of industrial cooling solutions. This project represents the pinnacle of our achievements to date, setting new benchmarks not only for the UK dairy sector but for the global dairy industry as a whole. The collaboration between Penmann, Clauger, and our client showcases what can be achieved when innovative technology meets deep industry expertise, and we look forward to delivering a system that will serve as a model for the future of dairy product cooling.