Case Study: how we dramatically reduced costs and improved the efficiency of a food packaging plant
Our Peak Nitrogen Generation System eliminated the need for Liquid Nitrogen Dewars. In the process we removed inconsistencies of Nitrogen supply and problems such as running out of gas and freezing piping.
About Our Client
The client is a family-owned distributor specializing in fresh produce and specialty foods, serving a variety of customers including retail, wholesale, and foodservice businesses. Operating in the competitive Toronto market, they rely heavily on Modified Atmosphere Packaging (MAP) to maintain product quality and freshness. The company's priority is operational efficiency and maintaining consistent product quality to meet the demands of their customers.
The Problem
Before engaging with us, the client faced significant operational challenges due to their reliance on liquid nitrogen dewars. This system was costly and inefficient, costing approximately $5,000 per month. Key issues included:
- Freezing Issues: The liquid nitrogen system often caused freezing in the piping and valves of the food packaging machines, leading to malfunctions and inconsistent gas flow.
- Production Interruptions: Switching out dewars required halting production, which disrupted operations and impacted productivity.
- Invisibility in Usage: The client lacked visibility into nitrogen usage, making it difficult to monitor and optimize consumption.
- Supply Inconsistencies: Frequent delivery delays and insufficient storage capacity resulted in running out of nitrogen, creating further disruptions.
These problems not only increased operational costs but also posed risks to the quality and timeliness of their production.
Engagement Details
We installed a nitrogen generation system specifically designed and certified for food packaging applications, addressing the client’s unique needs.
The process started with a thorough nitrogen demand analysis, where we worked closely with the client to understand their challenges and expectations. Here’s what we discovered:
- Freezing Issues: The liquid nitrogen from dewars caused icing on the pipes because of its extremely low temperatures. This led to malfunctioning valves, frozen flow meters, and disruptions in the flow of nitrogen, resulting in inconsistent packaging.
- Production Downtime: Replacing dewars often meant halting production, leading to delays and inefficiencies.
- Unreliable Supply: The client frequently ran out of nitrogen due to inconsistent deliveries, creating unnecessary stress and operational interruptions.
With these challenges in mind, we designed a custom solution to provide a continuous, 24/7 nitrogen supply at 600 liters per minute. The system didn’t just include a nitrogen generator—it was a complete setup, including a feed air system to ensure the nitrogen met strict food-grade standards.
Our approach included:
- Needs Assessment: We evaluated the client’s specific requirements, focusing on improving efficiency and reliability.
- Custom System Design: Our team of engineers created a tailored system to deliver consistent results, meeting both production demands and food safety standards.
- Turnkey Installation: We handled the installation from start to finish, ensuring a smooth integration into the client’s operations with minimal disruption.
- Ongoing Support: After the system was up and running, we provided training and set up a maintenance schedule to keep everything operating at peak performance.
By replacing the outdated liquid nitrogen system with this on-site generator, the client now has a reliable, cost-effective nitrogen supply that runs seamlessly—no more interruptions, no more freezing issues, and no more worrying about deliveries.
The Result
We implemented a nitrogen generation system specifically certified for food packaging applications, addressing key operational challenges. The new system eliminates freezing in the lines, ensures uninterrupted production, and delivers a rapid return on investment within 18 months. Beyond this, the client is set to benefit from virtually cost-free nitrogen supply for the next 15 years.
The results were transformative for the client’s operations:
- Significant Cost Savings: With an ROI achieved in just 18 months, the client is positioned to save substantially over the system’s 15-year lifespan.
- Enhanced Efficiency: The Peak nitrogen generation system has eliminated production halts previously caused by dewar replacements and supply interruptions.
- Reliable and Consistent Supply: The system provides a steady and dependable nitrogen output, free from freezing issues or flow inconsistencies.
- Improved Visibility and Control: The client now has the tools to actively monitor and manage nitrogen usage, optimizing resource allocation and improving overall operational efficiency.
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About Specialty Gas
Speciality Gas is your one-stop shop for all your Oxygen and Nitrogen generation needs. Our solution specialists manage your project from the initial discovery to after sales service. We install and service Peak and Airsep O₂ and N₂ generators as well as the Kaeser compressed air systems that power them. Our team has a combined 172 years of experience with specialty gas installations.
Generating N₂ or O₂ at your facility is easier than you’d think. With ROIs of 12 to 18 months in most cases, you can’t afford not to investigate the endless possibilities! Contact us now to see how we can help you save money by having your own supply of nitrogen or oxygen.
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