Grated cheese just got greater

The Challenge

DCS Food Ingredients manufacture at The Cheese Factory near to Bideford, Devon producing a range of cheese-based ingredients for other food product manufacturers.  They have used N2 for modified atmosphere packaging (MAP) for many years when packaging grated and sliced cheese into bags between 1kg and 5kg in size.  Also known as ‘gas flushing’.  This is a simple process of flushing packaged foods with inert high purity nitrogen in order to reduce the oxygen level below ≤1% in each bag, which slows down aerobic decay and deterioration caused by oxidisation, resulting in fresher food both in terms of taste and appearance. The use of nitrogen as a filler gas also provides a pressurised atmosphere that prevents packages from collapsing, and gives a smoother result than vacuum packaging.

Their existing Nitrogen gas generator was around 10 years old and could not consistently meet the site’s demand. In addition, due to high product demand, the factory was expanding and required more nitrogen. Wishing to explore their options at this crucial stage, they approached Maziak for advice. 

The Solution

The goals were to improve and optimise air compressor energy efficiency with the latest technology, reduce existing and future N2 costs and improve accessibility to energy data and the performance statistics of the N2 gas generation system.

This was achieved via the installation of an HPC SK22 fixed speed compressor with ultra premium efficiency IE4 motor and Sigma Controller; a Parker OFASHL055 Desiccant Dryer and a market-leading Parker NitroSource N2 generator. 

The features of this unit (pictured) include:

  • Operates from a standard factory compressed air supply
  • Delivers 5% down to 10ppm oxygen content, without the need for additional purification
  • Fully automatic operation and economy mode
  • Built-in oxygen analyser for continuous purity monitoring with digital and analogue outputs for remote monitoring
  • Plus: alarm capabilities, user friendly control interface, compact design and modular concept

The Result

DCS’s new system has delivered major cost savings and improved reliability.  The new and innovative equipment has also led to significantly improved energy efficiency.