Energy-Efficient Expansion for a Global Avocado Producer

For over 75 years, our client has been a globally recognised leader in the production of avocado products, while also supplying citrus fruits, blueberries, and cherries to international markets. With operations spanning 17 countries and a workforce of over 8,000 employees, the company has experienced steady growth since its founding in 1949.

A key strategic priority for the business is achieving net zero emissions, making energy efficiency a critical focus—especially at their UK processing and packing facility in Spalding, Lincolnshire. As the site prepared for expansion to increase production capacity, the challenge was clear: how to support this growth without increasing energy consumption.

Having recently installed an energy-efficient Atlas Copco compressed air system in the main factory, the client turned to Maziak once again to deliver a scalable, cost-effective solution that aligned with their sustainability goals.

A comprehensive site survey revealed that the existing compressed air distribution system had evolved organically over time, resulting in a network of spurs and branches that caused air starvation and pressure drops in key areas.

Rather than recommending additional compressor units—which would increase both capital and energy costs—Maziak proposed a smarter approach:

• Redesign the distribution network into a ring-main system, ensuring consistent air pressure and volume across the entire site.
• Install a strategically located local storage tank to support peak demand and stabilise pressure.
• Utilise Atlas Copco’s Airnet smooth-bore aluminium piping, selected for its durability, efficiency, and ease of installation.
• Conduct precise pipe sizing calculations to optimise flow and minimise pressure loss.

This engineering-led approach allowed us to meet the increased air demand without expanding the compressor plant—delivering both operational and environmental benefits.

• Energy Efficiency Maintained: Despite the site expansion, energy consumption remained stable, supporting the client’s journey toward net zero.
• Improved System Performance: Air starvation and pressure drops were eliminated, resulting in smoother, more reliable production processes.
• Future-Proofed Infrastructure: The new ring-main system provides a scalable foundation for future growth, without compromising efficiency.