Brewery Boiler Upgrade Delivers £256K Annual Savings

When a leading global brewery set out to reduce energy costs, improve reliability, and meet ambitious sustainability targets, they turned to Projective for a solution that would deliver real impact.

The client’s existing steam system was outdated, inefficient, and increasingly unreliable. It couldn’t keep pace with production demands or environmental goals. The challenge was to design and deliver a modern boiler house that would improve performance, reduce operational costs, and support future growth, while ensuring full compliance and minimal disruption.

We began by understanding the site’s current and future needs. Using our Process Energy Model, we developed a detailed steam demand profile to guide system sizing and design.

Our solution included:

• Three high-efficiency boilers with flue gas economisers
• Integrated heat recovery from condensate and boiler blowdown
• Water reuse system using treated RO concentrate as boiler feed water

This approach reduced water intake, cut effluent discharge, and improved overall system efficiency.

As Principal Contractor under CDM Regulations, Projective delivered a fully integrated, high-performance boiler house with a total capacity of 40MW. Purpose-built for long-term resilience and adaptability, the system is engineered to evolve with the brewery’s operational needs, ensuring efficiency, reliability, and compliance at every stage. Key features and benefits include:

• Future-ready design – Built to accommodate fluctuating production demands without compromising performance.
• High operational resilience – Robust engineering ensures consistent reliability under varying load conditions.
• Energy-efficient systems – Advanced technologies maximise heat recovery and minimise energy waste.
• Regulatory compliance – Fully aligned with CDM Regulations and environmental standards.
• Scalable infrastructure – Designed with flexibility to support future expansion and innovation.

• High efficiency, modulating burners for precise load matching.
• Advanced control systems with load sequencing, remote monitoring, and predictive maintenance.
• Automated lead/lag rotation to balance boiler runtime and extend asset life.