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Delivering a Site-Wide Cooling Upgrade for Thatchers Cider
Here at Newsome, we are pleased to have successfully completed a major cooling system upgrade for Thatchers Cider, delivering a modern, efficient and environmentally improved solution across multiple areas of their production facility.
The project involved the replacement of existing cooling towers serving the CT1, M&L and Velo areas with high-performance adiabatic air blast coolers. The objective was to improve efficiency, reduce water consumption and modernise ageing infrastructure, while maintaining the required cooling performance to support production processes.
From the outset, careful consideration was given to site constraints, including available space, equipment footprint and noise levels. Our design approach ensured that all new equipment could be integrated within the existing layout while delivering the required cooling capacity.
For the CT1 system, space limitations meant that a single replacement unit was not viable. To address this, we designed a solution using three adiabatic coolers, each delivering 745 kW of cooling, providing a combined capacity of over 2.2 MW. This allowed us to meet performance requirements while working within the physical constraints of the existing plant area.
At the Velo and M&L locations, the existing cooling towers were positioned side by side on a shared plinth. Due to the size of the new equipment, it was not possible to install both units in the same location. We therefore developed a revised layout, retaining one unit in the original position and relocating the second to a more suitable area adjacent to the building, closer to the plant it serves.
To ensure continuity of operations throughout the upgrade, we installed a temporary cooling solution prior to removing the existing CT1 tower. This allowed production to continue without interruption while the new systems were installed and commissioned.
The project was delivered on a full turnkey basis, including the removal and disposal of existing equipment, installation of new adiabatic systems and integration with the site’s existing infrastructure. Where possible, we reused existing pipework to reduce waste and minimise disruption, while new stainless steel pipework and pump systems were installed where required to support the upgraded configuration.
All systems were fully tested, pressure checked and commissioned by our engineering team, ensuring reliable performance from the point of handover. The transition to adiabatic cooling technology provides several long-term benefits for the site. Water consumption has been significantly reduced, as the new systems require far less water than traditional cooling towers. The removal of chemical dosing also simplifies ongoing maintenance and reduces operational complexity.
In addition, the use of variable speed fan technology allows the system to operate efficiently under varying load conditions, reducing energy consumption while maintaining consistent cooling performance.
Noise reduction was also a key consideration, with equipment selected and configured to operate at lower sound levels, ensuring minimal impact on the surrounding environment. This project demonstrates our ability to deliver complex cooling upgrades within live production environments, balancing performance requirements with practical site constraints. By combining detailed design, careful planning and experienced installation, we have provided Thatchers Cider with a reliable and efficient cooling solution that supports both operational and environmental objectives.
If you are considering upgrading your cooling systems or exploring more efficient alternatives to traditional cooling towers, contact Newsome to discuss how we can support your project.