HomeCase studiesDe-Streaming Without Disruption: CHP for a Global Consumer Goods Manufacturer

De-Streaming Without Disruption: CHP for a Global Consumer Goods Manufacturer

Flexible onsite generation replacing an ageing steam boiler at a major UK production facility
A global consumer goods manufacturer is modernising the energy infrastructure at a major UK production facility, moving the site away from steam through a phased de-steaming programme. The first phase is now running: a 2G avus 1600e combined heat and power (CHP) unit generating 2,032 kWe of electricity and 2,149 kW of recoverable heat, housed in a bespoke container installed within the site’s existing boiler room in place of an ageing steam boiler. sections produced to tolerances of less than 3 mm to accommodate tight spatial constraints. From a process integration perspective, the existing steam boiler infrastructure included an unused waste heat stream, allowing for a straightforward connection to the CHP system and maximising overall efficiency with minimal disruption to operations. Designed with future adaptability in mind, the CHP installation is fully H₂-ready and compatible with alternative gaseous fuels, supporting long-term flexibility as energy requirements evolve.

Facts & figures

Application:
Manufacturing industry
Country:
United Kingdom
CHP:
avus 1600e
Output el/th (kW):
2032 / 2149 kW
Operator:
Global Consumer Goods Manufacturer

The cogeneration project 

Re-engineering a site’s heat supply while production continues is the hard part of any de-steaming programme. The CHP unit was specified to bridge that transition. It supplies flexible thermal energy to supplement site demand throughout the changeover, so each subsequent phase of the programme can proceed without interrupting manufacturing. 

 

Intelligent load regulation modulates the unit’s output against live site demand and the site’s existing solar array, minimising imported electricity while keeping the connection fully compliant with G100 v2. Heat that would otherwise be bought as fuel is captured and put to work, cutting energy costs and strengthening the site’s energy autonomy. 

 

Speed mattered. With prime movers available, 2G delivered and handed over the complete installation within five months of order confirmation, keeping the wider upgrade programme on schedule and the site producing throughout. 

 

Like every current 2G engine, the unit is hydrogen-ready: it runs on natural gas today and converts to hydrogen or a hydrogen blend when supply reaches the site, with no engine swap required. For a manufacturer working towards long-term decarbonisation targets, that keeps the next step open.