Premier Foods, Carlton Bakery – Replacement of Aeration System

FLI CAP Technology delivered a major biological aeration system upgrade for Premier Foods’ Carlton Bakery in South Yorkshire, one of the UK’s largest food manufacturing facilities producing over 130 million packs of cake annually.

The existing effluent treatment plant, originally constructed in 1999, relied on aeration blowers that were approaching the end of their operational life. FLI CAP Technology was appointed to carry out a full technical review of the site’s biological aeration and mixing systems and develop a modern replacement solution.

Following detailed evaluation, FLI CAP Technology designed and installed a new aeration system comprising:

• Fine bubble diffused aeration technology for improved oxygen transfer efficiency
• Variable speed screw blowers delivering 30–40% greater efficiency than the original lobe blowers
• Acoustic enclosures for reduced noise emissions
• Updated dissolved oxygen, pH, temperature monitoring and flow control systems
• Control software modifications and automation upgrades

To ensure continued compliance and uninterrupted operation during installation, a temporary aeration blower system was provided throughout the project.

Measured Performance Benefits

The upgraded system delivered significant measurable improvements:

• Annual power costs reduced from £260,000 to £57,000
• Annual CO₂ emissions reduced from 193,000 kg to 42,000 kg
• Average operating power reduced from 110 kW to 24 kW

FLI CAP Technology delivered the full project scope, including design, equipment supply, mechanical and electrical installation, removal of existing equipment, software modifications and commissioning.

The project was completed on programme, on budget, and fully achieved the agreed performance targets, while maintaining full operational compliance throughout the upgrade.