Case Study
Process Chilled Water System – Signature Flatbreads, Dunstable
Overview
Client: Signature Flatbreads Ltd
Industry: Food Manufacturing
Presence: Design, supply, installation, and commissioning of a new process chilled water system.
Project Overview: Penmann Climatic Systems Ltd was appointed by Signature Flatbreads to design and install a new process chilled water system at their Dunstable production facility. The upgraded installation replaced an ageing system with a fully integrated solution that improves cooling stability, increases capacity and supports consistent dough preparation and production performance.
Project Value Range: £ – Confidential
Penmann Climatic Systems Ltd was appointed by Signature Flatbreads to design and install a new process chilled water system at their Dunstable production facility. The project was undertaken to improve the stability and efficiency of the site’s cooling network, which plays a vital role in maintaining consistent dough preparation and production line performance. The new installation replaced an ageing, unreliable setup with a fully integrated system providing greater capacity, redundancy, and energy control, ensuring stable operation across all process areas.
Project Objectives
The main aims of the project were to:
- Deliver a stable chilled water supply to maintain precise temperature control for dough processing.
- Improve operational reliability and remove dependency on temporary equipment.
- Increase system efficiency and reduce energy consumption.
- Provide redundant capacity to protect against downtime.
- Integrate with the site’s existing process control systems for automatic regulation and monitoring.
Design and System Configuration
Penmann’s engineering team carried out a full site review to understand production cooling loads and flow requirements. The new design was centred around a high-efficiency chiller plant, variable-speed pumps, and optimised distribution pipework to ensure consistent flow and temperature across the production process.
The system was configured to maintain process water temperatures within a tightly controlled range, enabling uniform dough conditions and reducing batch variation. New control logic was programmed to provide smooth load sharing between chillers and to respond dynamically to production demands, avoiding temperature instability during peak periods.
The installation also included upgraded filtration and monitoring equipment to protect downstream machinery and maintain water quality.
Installation and Commissioning
Penmann supplied, installed, and commissioned the complete system within an active production environment, coordinating closely with Signature Flatbreads’ engineering and operations teams to minimise disruption.
Key works included:
- Replacement of the existing chiller plant with new, energy-efficient units.
- Installation of variable-speed primary and secondary pumps for accurate flow control.
- Integration of a new control panel for full system automation and data logging.
- Commissioning of the chilled water circuit and performance testing under live operating conditions.
The project was delivered on schedule, ensuring continuous cooling capability throughout the changeover process.
Results and Benefits
Following completion, Signature Flatbreads achieved a more stable and energy-efficient process cooling system, with improved temperature accuracy and reduced plant downtime. The new system supports consistent product quality and provides additional resilience for future expansion.
The installation demonstrates Penmann’s ability to deliver turnkey process cooling solutions for the food manufacturing sector—combining technical precision, energy awareness, and minimal production disruption.