Case Study
Blast Cooling System Upgrade for Park Cake Bakeries
Overview
Client: Park Cake Bakeries in Oldham, Greater Manchester
Industry: Food Manufacturing
Presence: Turnkey Blast Cooling and Process Cooling Upgrade
Project Overview: Newsome delivered a complete turnkey blast cooling and process cooling upgrade for Park Cake Bakeries in Oldham, replacing ageing refrigeration infrastructure with a modern low temperature glycol cooling system designed to improve efficiency, cooling performance and future production capacity. The project included new blast chill rooms, holding area cooling, chilled storage systems and a 408 kW air-cooled chiller using lower GWP R454B refrigerant, providing reliable long-term temperature control for the bakery’s manufacturing processes.
Newsome was appointed to deliver a complete turnkey upgrade of the product cooling and blast chilling systems at Park Cake Bakeries’ production facility in Oldham, Greater Manchester. The project formed part of a wider strategic investment programme focused on modernising the bakery cooling process to meet both current production demands and future operational requirements. The scope included the redesign and reconstruction of the blast chilling process, replacement of the ageing refrigeration plant and installation of a new high-performance cooling infrastructure designed around efficiency, reliability and long-term operational flexibility.
The upgrade involved removal of the existing roof-mounted refrigeration equipment and associated pipework, redesign of the cooling arrangement and installation of a new chilled glycol cooling system serving multiple blast chill rooms, holding areas and chilled storage environments across the facility. Newsome delivered the project as a full turnkey solution, managing all stages from strip out and structural preparation through to installation, commissioning and final handover.
The Challenge
The existing bakery cooling infrastructure required significant redevelopment to support evolving production requirements and improve long-term operational performance. The existing blast chilling and holding areas required improved cooling capability, more stable temperature control and a system better suited to the demands of modern bakery production.
The project presented several engineering and logistical challenges. Existing refrigeration equipment located on the roof required removal while maintaining safe site operation. Structural modifications were also necessary to support the installation of new plant equipment and associated access infrastructure. Within the production areas, the blast chill rooms and holding spaces required carefully designed airflow and cooling arrangements capable of delivering rapid and consistent product cooling without compromising environmental stability or operational efficiency.
In addition, the system needed to operate using low temperature glycol while maintaining reliable performance under demanding bakery production conditions.
Newsome’s Turnkey Solution
Following detailed site meetings, review of the User Requirement Specification and extensive duty calculations, Newsome developed a complete cooling solution tailored specifically to the operational requirements of the site.
The project included:
- Removal of existing refrigeration and cooling infrastructure
- Installation of new roof-mounted process chiller plant
- Structural steelwork modifications and access improvements
- Blast chiller cooling system installation
- Holding area cooling systems
- Chilled storage cooling systems
- New insulated stainless steel pipework infrastructure
- Controls integration and commissioning
To ensure efficient project delivery, Newsome provided a dedicated full-time site manager throughout the anticipated twelve-week programme. This ensured close coordination between installation teams, site operations and project scheduling throughout all phases of the works.
Roof Plant Installation
A major part of the project involved replacement of the existing roof-mounted refrigeration equipment with a new high-capacity air-cooled chiller system. Newsome installed an NX2-G06-Y/K/0808 air-cooled packaged chiller capable of delivering over 408 kW of cooling at a supply temperature of -8°C. The chiller was specifically selected to support multiple cooling applications across the bakery process while maintaining stable low temperature glycol performance.
The unit operates using R454B refrigerant, a lower Global Warming Potential refrigerant offering substantially reduced environmental impact compared with older refrigerants traditionally used within industrial cooling systems. The chiller was installed onto new secondary galvanised steelwork above the existing roof structure, complete with wraparound access walkways, edge protection and access stair systems to improve long-term maintenance accessibility and operational safety.
The system was designed to operate using a 70% water and 30% glycol solution, providing freeze protection and stable low temperature performance throughout the blast chilling process.
Blast Chiller Cooling System
The blast chilling stage represented one of the most critical areas of the bakery cooling process. Each blast chill room required approximately 90 kW of cooling duty, with systems designed to support rapid cooling cycles while maintaining stable airflow distribution across the product. Newsome installed floor-mounted fan coil cooling units within each blast chill room. These units were connected to the central glycol cooling system via insulated and clad stainless steel pipework.
Each blast chill system was configured to operate on controlled cooling and defrost cycles, ensuring stable operation and reliable product cooling performance throughout production. Particular attention was given to airflow management within the blast chill rooms. Newsome incorporated punched plenum plate wall arrangements designed to provide even airflow distribution across the product, improving cooling consistency throughout the process.
The cooling units utilised epoxy-coated components and corrosion-resistant materials suitable for demanding food manufacturing environments.
Holding Area Cooling
Following the blast chilling stage, products moved into a holding area requiring controlled low temperature conditions. To support this process, Newsome installed ceiling-mounted cooling units configured in a duty-duty-standby arrangement. This design provided operational resilience while ensuring stable cooling performance during continuous production.
The holding area cooling system was integrated into the same glycol-based cooling infrastructure serving the blast chill rooms, simplifying system management while maintaining efficient operation. Automated controls and modulating valve arrangements ensured accurate temperature regulation and responsive operation throughout varying production conditions.
Chilled Storage and Post Cooling Areas
In addition to the blast chill and holding systems, Newsome also upgraded cooling systems serving chilled storage areas and post-cooling environments within the bakery.
New fan coil cooling units were installed to maintain stable low temperature conditions within Fridges 410 and 414, supporting product stability and controlled storage conditions. The selected cooling equipment provided high airflow performance combined with efficient low temperature operation, ensuring consistent environmental conditions across all process stages.
Pipework and Infrastructure
A substantial new pipework network was installed throughout the facility to connect the various cooling systems back to the central chiller plant.
Newsome installed insulated and clad stainless steel pipework designed specifically for low temperature glycol operation. Pipework layouts were engineered to support stable flow rates, minimise pressure losses and maintain efficient thermal performance across the entire cooling network. Condensate drainage systems were also integrated throughout the installation, including trace heating and insulation where required to protect against freezing and ensure reliable drainage operation.
Controls and Commissioning
Each process area was supplied with local control systems designed to integrate with site operational requirements. Modulating control valves and automated system controls allowed accurate regulation of cooling output and operational sequencing throughout the bakery process. Following installation, Newsome carried out full commissioning of the cooling systems, verifying cooling capacities, glycol flow rates, control operation and overall system performance. This commissioning process ensured that all cooling stages operated in accordance with the design requirements and production objectives established during the project planning phase.
Energy Efficiency and Environmental Performance
Energy efficiency and environmental responsibility formed important parts of the project design. The use of modern air-cooled chiller technology combined with lower GWP refrigerants allowed the bakery to improve environmental performance while maintaining the demanding low temperature conditions required by the production process.
The selected R454B refrigerant provides significantly reduced Global Warming Potential compared with traditional refrigerants previously used within industrial refrigeration applications. Combined with modern compressor technology and advanced controls, the upgraded cooling system delivers improved operational efficiency alongside enhanced process stability.
Project Outcome
The completed installation has provided Park Cake Bakeries with a modernised bakery cooling infrastructure designed around long-term operational reliability, process efficiency and future production flexibility. The new blast chilling and holding systems now provide stable low temperature performance across critical stages of the bakery process, supporting product quality and operational consistency. By delivering the project as a complete turnkey solution, Newsome successfully managed all aspects of the installation while minimising disruption to the operational facility.
Conclusion
This project demonstrates Newsome’s capability to deliver complex process cooling and blast chilling projects within demanding food manufacturing environments. By combining detailed engineering design, modern low temperature cooling technology and full turnkey project management, Newsome delivered a cooling solution tailored specifically to the operational requirements of Park Cake Bakeries.
The completed system provides improved process control, enhanced operational efficiency and long-term cooling resilience, supporting both current production demands and future site development.