Pennine are recognised for its experience in chilling poultry. Following detailed discussions with the client, they were awarded the project to design and deliver the new air-chiller facility, as they supply a complete solution that includes the conveying system. The objective was to provide a reliable, energy-efficient solution that supports increased production throughput while replacing an ageing high-GWP HFC refrigeration plant.
Client Overview
The client is a major supplier in the poultry processing industry, operating a high-demand production facility where reliability, product quality, and throughput are critical to daily operations. With future growth in mind, the client required an upgraded air-chilling solution to support higher processing volumes while aligning with broader sustainability and energy-efficiency goals.
Expertise/Services Delivered
Pennine Refrigeration Systems was appointed to design, supply and deliver a new mechanised chilling facility for a major poultry-processing factory. The project was to increase processing capacity to 12,500 chickens per hour and included the design and integration of full refrigeration and conveying equipment with the existing process line. Pennines’ design included all support steel in stainless steel, conveyor track, and over 4 kilometres of case-hardened chain. The refrigeration system utilised two multi-compressor CO2 plants and 10 refrigeration evaporators.
The project was developed in close collaboration with the client to ensure the new facility met both immediate operational requirements and longer-term production demands.
What Was the Challenge?
The client’s existing air chiller and refrigeration plant were outdated and no longer met the site’s operational requirements. The site required increased production throughput to meet rising demand and reduce the environmental impact of the existing inefficient refrigeration plant, whilst also adhering to the client’s mission statement.
A further challenge was integrating the existing process line into the new air chiller line within a very tight installation window. The works had to be carefully planned and executed to avoid disrupting the factory’s ongoing operations and to prevent costly downtime.
What was the Solution?
The upgraded design increased process capacity to 12,500 birds per hour, boosting throughput and improving plant performance and system reliability. The new facility was also designed to allow future heat recovery, enabling the client to realise additional energy optimisation opportunities in subsequent project phases.
A key factor in the project’s success was detailed planning and close coordination with the client throughout the design and delivery phases. Because the existing process line needed to be integrated with the new air chiller line during a very limited shutdown window, the installation programme was developed to ensure all critical works were completed efficiently and safely.
Pennine’s experienced team worked to minimise operational disruption, carefully managing the integration process to ensure production continuity at the site. The installation programme was developed to ensure all critical works were completed efficiently and safely.
This approach was essential to delivering a seamless transition from the old plant to the new refrigeration system.
What were the Results?
The project marked a significant step forward for the client’s operations. By installing a new CO2-based refrigeration solution, the site benefited from improved reliability, greater production throughput and a more energy-efficient refrigeration system.
The removal of the previous high-GWP HFC refrigerant also delivered an important environmental benefit, helping the client reduce the impact of its refrigeration infrastructure and move towards a more sustainable operating model. In addition, the plant has been designed with future heat-recovery capability, giving the client further opportunity to improve overall site energy performance.
Do You Have Specific Numbers You Can Share?
Yes, the project delivered several clear measurable outcomes:
- Over 1MW of cooling capacity delivered through two CO2 plants
- Production capacity increased to 12,500 birds per day
- This represented a 25% increase in processing volume
- Removal of a high-GWP HFC refrigerant and replacement with a high-efficiency CO2 solution
- Improved system reliability and provision for future heat recovery
The new facility was specifically designed to support future production growth while improving refrigeration performance and efficiency.
Key project figures include:
- 2 x CO2 plants installed
- Over 1 megawatt of cooling capacity
- 12,500 birds per hour process design capacity
- 25% uplift in throughput
- Reduced environmental impact through the replacement of the legacy high-GWP HFC plant
This project highlights Pennine Refrigeration Systems’ ability to deliver advanced, energy-efficient refrigeration and conveying solutions for demanding food production environments. By combining increased throughput, improved operational reliability and the transition to a lower-impact CO2 system, Pennine delivered a solution that not only meets the client’s current needs but also supports future growth and sustainability ambitions.
Through careful planning and expert delivery, the project was completed within a challenging operational window, demonstrating Pennine’s capability to execute complex upgrades with minimal disruption to production-critical facilities.
