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Delivering High-Performance Cooling for a Leading Bakery Facility
Here at Newsome, we are delighted to have completed a high-performance air handling upgrade for a Manhattan Spiral Cooler at a major UK bakery production facility. The project was focused on improving temperature consistency, achieving lower product core temperatures and removing the long-standing challenges associated with unconditioned ambient air.
The existing system relied entirely on outside air, which led to significant seasonal variation. During colder months, the spiral cooler experienced overcooling, while in warmer conditions the available cooling capacity was not sufficient to maintain stable operation. This inconsistency created challenges for production and made it more difficult to achieve the precise product temperatures required for reliable downstream cutting.
In addition to these process limitations, the existing air handling unit had reached the end of its operational life. Installed in 2004, it was no longer suitable from a hygienic or efficiency perspective and was operating with a belt-driven fan system that required ongoing maintenance.
Working closely with the client, we designed a solution that retained the existing airflow characteristics of the spiral cooler while introducing full control over the supply air condition. The new system enables fresh air to be tempered by mixing with return air during low ambient conditions and cooled via a chilled glycol coil during warmer periods. This approach removes reliance on external weather conditions and provides consistent performance throughout the year.
At the centre of the upgrade is a new air handling unit constructed using hygienic materials and fitted with high-efficiency EC direct-drive fans. This delivers improved energy performance, reduced maintenance requirements and more precise airflow control. The unit also incorporates multi-stage filtration and a high-performance cooling coil designed specifically for the operating environment.
To support the required cooling duty, we installed a dedicated roof-mounted packaged chiller delivering approximately 485 kW of cooling. The system uses a low Global Warming Potential refrigerant, supporting both performance and environmental considerations. The chiller is connected to the air handling unit via a new stainless steel pipework system, complete with insulated supports, control valves and fully commissioned controls. The installation was carefully planned and executed to minimise disruption to the client’s operations. The existing unit was removed in sections using a crane lift, and the new system was installed onto the existing infrastructure with upgraded duct connections and improved insulation throughout.
Since completion, the system has delivered a significant improvement in performance. The spiral cooler now benefits from stable, controlled air conditions regardless of seasonal changes, enabling more consistent product core temperatures and improved process reliability.
This project highlights our ability to deliver engineered solutions that solve real production challenges while improving efficiency, hygiene and long-term reliability. It also demonstrates how modern air handling and cooling technology can transform performance within demanding food manufacturing environments.
We are proud to have supported the client on this project and look forward to continuing to deliver high-quality environmental control solutions across the food manufacturing sector.