SUSTAINABILITY SOLUTIONS provision to the packaging lines.
To supply the nitrogen generator, Santa Maria UK installed a GA11 VSD, an 11-kW variable speed rotary screw compressor, providing a dedicated and energy-efficient compressed air source. This is supported by a WSD75+ moisture separator and a CD30+ desiccant dryer delivering a minus 40°C pressure dew point.
A comprehensive filtration package, including a QDT activated carbon tower and high efficiency particle filters, completed the air treatment system. Together, these components ensure that the compressed air feeding the nitrogen generator meets ISO 8573-1 air quality standards for particles, water and oil content.
Maintaining this air quality classification is critical. PSA nitrogen generators rely on clean, dry compressed air to protect the carbon molecular sieve beds and ensure consistent downstream gas purity. By treating the inlet air to ISO 8573 standards before separation takes place, the system safeguards both generator performance and nitrogen quality for food production.
FINANCIAL BENEFITS
While the environmental case was compelling, the strength of the return on investment ultimately made the project an easy decision. Instead of ongoing expenditure tied to liquid nitrogen deliveries, tank rental and potential supply volatility, Santa Maria UK now operates its own on-site nitrogen generation system with predictable electricity and servicing costs. The installation is projected to deliver annual savings of £56,243, with a projected payback period of approximately one year. Installation was delivered by T&G Compressors, with Atlas Copco commissioning the system. The equipment is situated within the factory environment and was integrated into existing operations without disruption to production. “Nobody has noticed any difference on the factory floor,” Godfrey adds. “That was the key indicator for me that everything was working exactly as it should.”
A BLUEPRINT FOR WIDER ADOPTION For Atlas Copco, the project illustrates how on-site gas generation can support both sustainability objectives and operational resilience. Oliver Ford, Business Development Engineer for Industrial Gases at Atlas Copco, comments: “By moving from bulk liquid supply to on-site nitrogen generation, Santa Maria UK has removed the emissions associated with production and transport while gaining full control over its gas supply. The system is sized for peak demand, includes redundancy, and delivers the required purity for food applications. The outcome is a measurable carbon reduction of more than 12 tonnes per year alongside a rapid financial payback.” Santa Maria UK is the first site within the wider Paulig group to adopt on-site nitrogen generation. Daily operational checks have
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been incorporated into routine site walk- arounds, and Santa Maria UK is implementing energy monitoring to compare ongoing electricity costs against historic liquid nitrogen expenditure. With performance data now being gathered and validated, the Milton Keynes facility provides a model for other factories considering similar investments. “I’m genuinely impressed with the system,” says Godfrey. “It’s delivering exactly what we were promised. If it makes sense for our site, there’s no reason it couldn’t be adopted elsewhere.” For a business built on consistent flavour and quality, the right atmosphere inside every pack is essential. By generating its own nitrogen gas on site, Santa Maria UK has demonstrated that environmental improvement and operational efficiency can be achieved together, without compromise.
Atlas Copco Compressor Technique
www.atlascopco.com/en-uk/compressors
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