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Penmann Delivers Permanent Glycol Chiller Solution for Ambrosia Creamery in Lifton
We are pleased to have successfully delivered a new permanent glycol chiller system at the Ambrosia Creamery site in Lifton, Devon, on behalf of Premier Foods. The project marked a significant upgrade to the site’s cooling infrastructure, replacing temporary hire equipment with a high-efficiency, long-term solution designed to support both current production demands and future expansion.
Ambrosia Creamery required a robust and reliable system capable of maintaining precise temperature control across critical food manufacturing processes. Our brief was to design, supply, install and commission a new 1.1 MW glycol chiller system that would improve operational efficiency, reduce reliance on temporary equipment and align with Premier Foods’ wider sustainability objectives.
The new installation centres around an air-cooled chiller, selected to deliver strong performance across varying load conditions while operating with a low-GWP refrigerant. By adopting R1234ze refrigerant and variable-speed compressor technology, the system provides a future-proof solution that supports reduced energy consumption and lower environmental impact. The chiller was designed to achieve a glycol flow temperature of minus one degree Celsius and a return temperature of plus four degrees Celsius, using a monopropylene glycol mixture to suit the site’s process requirements.
Alongside the chiller, we installed a new buffer vessel, glycol pressurisation unit and pump skid, all engineered to deliver stable hydraulic performance and allow straightforward access for servicing and maintenance. The system footprint was carefully managed to fit within the existing plinth area, ensuring compatibility with the site layout while allowing room for future capacity growth.
Mechanical chiller installation works were planned around a controlled shutdown period to minimise disruption to production. The existing glycol tank was safely drained, and the reclaimed glycol was reused following installation. A new stainless-steel pump skid was installed beneath the tank, designed to maximise net positive suction head and improve long-term pump efficiency and reliability. Thin-wall stainless-steel pipework was routed across the mezzanine at high level to maintain clear access for site personnel before connecting externally to the chiller evaporator via purpose-designed supports fixed to the building structure.
All new pipework was fully insulated and clad to suit the operating environment, with removable insulation covers fitted to valves and flanges to support ongoing inspection and maintenance. Particular attention was paid to build quality and accessibility to ensure the system remains reliable throughout its service life.
Electrical installation and control formed a key part of the project delivery. We designed and installed a new pump control panel capable of serving four chilled-water pumps, providing both operational flexibility and future expansion capacity. Variable-speed drives were integrated to optimise pump performance, reduce energy use and maintain consistent system pressures. All cabling and containment were installed in accordance with current wiring regulations, with full testing and certification completed prior to commissioning.
The chiller itself was delivered to site by crane and carefully positioned beneath the existing canopy on anti-vibration mounts to minimise noise and structural transmission. Connection to the evaporator was completed using a full suite of isolation valves, strainers, metering stations and test points, allowing accurate commissioning and simplified future maintenance.
The project was delivered to a clearly defined programme aligned with production requirements and was completed and handed over in August 2023. Following commissioning, the system demonstrated stable performance, improved efficiency and reliable temperature control across the process.
The new glycol chiller installation has provided Ambrosia Creamery with a permanent, energy-efficient cooling solution that removes the need for temporary hire equipment while supporting long-term operational resilience. The project reflects our experience in delivering technically complex process cooling systems within live food manufacturing environments, combining engineering precision, careful planning and sustainable system design.
This installation further reinforces Penmann’s capability to deliver turnkey chiller and glycol cooling solutions for the UK food manufacturing sector, supporting performance, reliability and environmental responsibility.