Supporting reliable bakery production while progressing towards Net Zero
Warburtons is Britain’s largest bakery brand, producing a wide range of bakery products across multiple manufacturing sites nationwide.
With high-volume production lines supplying fresh bakery products to customers across the UK, reliable and efficient utilities are essential to maintaining production, product quality and business continuity.
Steam plays a critical role within Warburtons’ manufacturing processes, supporting applications including proofing, baking and other production-related activities. As a result, ensuring a consistent and reliable steam supply is fundamental to the day-to-day operation of the site.
As part of its wider sustainability strategy, Warburtons is also focused on reducing energy consumption, decarbonising its operations and progressing towards its long-term Net Zero ambitions.
It was against this backdrop that Warburtons began reviewing its existing steam generation infrastructure.
Modernising critical steam infrastructure
The existing steam plant was reaching a stage where replacement needed to be considered to improve long-term reliability, efficiency and maintainability.
However, the project represented more than simply replacing ageing equipment.
With steam generation forming an important part of the site’s overall energy consumption and manufacturing process, Warburtons saw an opportunity to invest in modern technology that could improve operational resilience while also supporting its wider sustainability and decarbonisation objectives.
The new system therefore needed to provide a combination of reliability, efficiency and flexibility, while also integrating effectively into an existing live manufacturing environment.
Key requirements included:
- High reliability and resilience
- Energy-efficient operation
- Reduced environmental impact and carbon emissions
- A compact footprint
- Ease of maintenance
- Seamless integration with existing infrastructure
- Strong technical and supplier support
- Minimal disruption during installation and commissioning.
Importantly, the new solution also needed to support Warburtons’ longer-term decarbonisation journey and provide a platform for future improvements.
Why CERTUSS?
Following its assessment of the available options, Warburtons selected CERTUSS based on the company’s understanding of its operational requirements and the ability of the proposed solution to meet the site’s reliability, efficiency and maintenance objectives.
CERTUSS’ technical expertise, proven track record and compact steam generator design were important factors in the decision, alongside the level of support provided throughout the project.
The ability to deliver a modern steam generation solution within the constraints of an operational manufacturing site was also a key consideration.
Integrating into a live manufacturing environment
As with many large-scale manufacturing facilities, space and maintaining production continuity were important considerations throughout the project.
The new CERTUSS steam generation system was designed to meet the site’s operational steam demand and was integrated into the existing steam distribution network and site controls.
This allowed the new equipment to support the existing manufacturing operation without requiring significant changes to the wider production process.
CERTUSS worked closely with Warburtons’ site team and project stakeholders throughout the design, installation and commissioning phases.
The project was managed with a strong focus on communication, technical support, safety and the operational requirements of the live manufacturing environment.
Reliability, efficiency and long-term sustainability
Since installation, the new CERTUSS system has provided Warburtons with improved operational reliability and greater confidence in its steam generation capability.
The modern equipment and controls provide an efficient and maintainable solution designed to support the site’s ongoing manufacturing requirements.
For Warburtons, however, the benefits extend beyond reliability.
The project forms part of the company’s wider sustainability and carbon reduction strategy, demonstrating how investment in critical utility infrastructure can contribute to both operational and environmental objectives.
The improved steam generation technology supports better energy utilisation while providing a modern platform that can contribute to future decarbonisation initiatives.
While improving resilience and long-term reliability was a primary objective, the project also demonstrates how modern steam technology can deliver multiple benefits through a single investment.
Creating a blueprint for future projects
One of the key outcomes of the project is its potential to provide a blueprint for similar improvements across Warburtons’ wider manufacturing network.
By combining resilience, efficiency and sustainability, the project demonstrates how businesses can modernise essential utility infrastructure while simultaneously supporting longer-term environmental objectives.
For Warburtons, the investment provides a modern steam generation solution today while helping establish a foundation for future decarbonisation initiatives.
A trusted partnership
Reflecting on the project, Warburtons highlighted the confidence that comes from having a modern, reliable and efficient steam generation system supported by a knowledgeable supplier.
The project has delivered operational improvements while also supporting the company’s longer-term sustainability ambitions.
Most importantly, it demonstrates that upgrading critical steam infrastructure does not have to be viewed purely as a replacement project. With the right technology and approach, it can become an opportunity to improve reliability, efficiency, maintainability and environmental performance at the same time.
Based on its experience, Warburtons would be happy to recommend CERTUSS to other manufacturers with similar steam generation requirements.
“The project has shown how businesses can combine resilience, efficiency and carbon reduction within a single investment, creating a practical blueprint for future decarbonisation initiatives.”
The result
Reliable steam generation. Improved efficiency. Enhanced maintainability. A platform for future decarbonisation.
The Warburtons project demonstrates the role modern CERTUSS steam generation technology can play in helping manufacturers protect critical production processes while progressing towards their wider energy and sustainability goals.
T +44 (0)121 327 5362
info@certuss.co.uk
www.certuss.co.uk
www.warburtons.co.uk