Case Study
Thatchers Cider – Site Cooling System Upgrade
Overview
Client: Thatchers Cider in Somerset
Industry: Food and beverage manufacturing (cider production)
Presence: Cooling Tower Replacement and Adiabatic Cooling Installation
Project Overview: Newsome delivered a full cooling system upgrade for Thatchers Cider, replacing ageing cooling towers with high-efficiency adiabatic air blast coolers across the site. The project improved energy efficiency, reduced water use, and maintained production through a carefully planned installation with temporary cooling support.
Newsome was appointed to deliver a full site cooling system upgrade for Thatchers Cider, replacing existing cooling towers with modern adiabatic air blast coolers across multiple areas of the facility. The project formed part of a wider initiative to improve energy efficiency, reduce water consumption and modernise ageing infrastructure.
The existing cooling towers serving CT1, M&L and Velo areas had reached a point where replacement was required. In addition to improving performance, the client aimed to reduce the environmental impact associated with water evaporation and chemical dosing typically required by traditional cooling towers.
A key requirement of the project was to deliver a solution that would maintain required process water temperatures while also addressing site-specific constraints, including space limitations, noise considerations and existing infrastructure.
Newsome’s Solution
Newsome designed and delivered a turnkey cooling solution, replacing all existing cooling towers with adiabatic air blast coolers. These systems were selected as a modern alternative, offering improved efficiency, reduced water usage and lower ongoing maintenance requirements.
CT1 Cooling Tower Replacement
The CT1 cooling tower presented a significant constraint, as the replacement equipment was required to fit within the same footprint as the original unit. Due to space limitations, a single unit capable of delivering the full cooling load was not feasible.
To overcome this, Newsome designed a system using three identical adiabatic coolers, each providing 745 kW of cooling, delivering a combined total of 2235 kW at design conditions. By splitting the load across multiple units, the system was able to meet performance requirements while remaining within the available space.
To ensure continuity of operations during the installation phase, Newsome deployed a temporary 1 MW cooling system, allowing the existing cooling tower to be safely disconnected and removed without interrupting production.
Velo and M&L Cooling Systems
The existing cooling towers serving the Velo and M&L areas were located side by side on a shared plinth. However, due to the size of the new adiabatic units, it was not possible to install both replacements in the same location. Newsome developed a revised layout, positioning one unit at the original location and relocating the second unit to an alternative position adjacent to the building, close to the plant it serves. This approach ensured optimal performance while overcoming site constraints.
The installed systems provide:
- Velo: 1 x adiabatic cooler delivering 805 kW cooling capacity
- M&L: 1 x adiabatic cooler delivering 1610 kW cooling capacity
Mechanical Installation and Integration
The project was delivered as a full turnkey mechanical installation, including removal of existing equipment, installation of new systems and integration with the existing infrastructure. For the CT1 system, new stainless steel pipework was installed to connect the three adiabatic units, with a common DN200 header and DN125 connections to each cooler. The system was designed to operate at a 10°C temperature differential, ensuring efficient heat rejection.
Existing pipework was reused where possible to minimise waste, reduce disruption and maintain cost efficiency. Where modifications were required, new flanges and connections were installed to ensure compatibility with the upgraded system. At both Velo and M&L locations, new stainless steel pipework and twin pump sets were installed, mounted on galvanised steel frames to provide reliable circulation. Internal scaffolding was used to access connection points, and new flanged connections were welded into place to integrate the new equipment.
All pipework was supported in accordance with British Standards and CIBSE guidelines, using appropriate bracketry and fixings to ensure long-term stability and performance.
Installation Challenges and Considerations
The project required careful planning to address a number of site-specific challenges. These included limited space, the need to maintain ongoing operations and the requirement to minimise disruption to existing systems.
Noise levels were also a key consideration, particularly given the operational nature of the site. Equipment was selected and configured to provide low noise output while maintaining required cooling performance. Logistics were managed using vehicle-mounted cranes to deliver and position equipment safely within the available space. In addition, internal and external scaffolding structures were installed to facilitate safe access during installation works.
Prior to installation, systems were dosed and chlorinated where required, ensuring safe removal of existing equipment. All works were carried out in line with agreed RAMS, with a structured project programme to ensure safe and efficient delivery.
Key Benefits
Reduced Water Consumption
The transition from traditional cooling towers to adiabatic systems has significantly reduced water usage, supporting environmental objectives and reducing operating costs.
Lower Maintenance Requirements
The removal of chemical dosing and reduced risk of contamination simplifies ongoing maintenance and reduces operational complexity.
Improved Energy Efficiency
Modern adiabatic systems with variable speed fans deliver efficient performance, reducing energy consumption while maintaining required cooling capacity.
Commissioning and Handover
Upon completion of installation, all systems were fully commissioned by Newsome engineers. This included filling, venting and pressure testing of all pipework, with certification provided to confirm system integrity. Control systems were configured to ensure that each adiabatic cooler operated efficiently, with variable speed fan control enabling performance to be adjusted based on demand.
The completed system was handed over with full documentation, providing the client with a reliable and efficient cooling solution aligned with operational requirements.
Improved Energy Efficiency
Modern adiabatic systems with variable speed fans deliver efficient performance, reducing energy consumption while maintaining required cooling capacity.
Low Noise Operation
Equipment was selected and configured to operate at low noise levels, ensuring minimal impact on the surrounding environment.
Flexible System Design
The use of multiple units and revised layouts allowed the system to be tailored to site constraints while maintaining performance.
Operational Continuity
The use of temporary cooling during installation ensured that production was not disrupted, allowing the upgrade to be completed without impacting operations.
A Modern Approach to Industrial Cooling
This project demonstrates the advantages of replacing traditional cooling towers with modern adiabatic systems. By reducing water consumption, lowering maintenance requirements and improving efficiency, the upgraded system provides long-term operational benefits.
The ability to adapt the system design to site constraints, while maintaining performance, highlights the importance of detailed engineering and practical experience in delivering complex projects.
Conclusion
Newsome successfully delivered a complete cooling system upgrade for Thatchers Cider, replacing ageing cooling towers with high-efficiency adiabatic air blast coolers across multiple areas of the site.
Through careful design, detailed planning and a structured installation approach, the project was completed safely and efficiently, with minimal disruption to ongoing operations.
The new system provides a reliable, efficient and environmentally improved solution, supporting the client’s long-term operational and sustainability objectives.
For more information on cooling system upgrades, adiabatic cooling solutions or turnkey HVAC Systems, contact Newsome today.