Fixed gas detection in the drinks industry

When most people think of gas detection, industries like oil, petrochemicals, and steel naturally come to mind. However, gas detection is equally critical in the brewing and beverage industry, where hazardous gases such as carbon dioxide (CO2) and nitrogen are commonly used.

The Challenge: Gas Safety Risks in a Cider Factory

A prominent cider factory in the Midlands, producing over 12 million litres of premium cider annually, recognised the need to enhance its gas safety measures. As a facility with high production volumes and multiple confined spaces, the risk of hazardous gas accumulation was significant. CO₂, generated in large quantities during fermentation, and nitrogen, used throughout the brewing process, posed potential dangers to employees.

The award-winning cider company, which operates across three UK sites, reached out to Shawcity for expert support in monitoring and managing gas levels across its premises.

The Solution: A Tailored Fixed Gas Detection System

Shawcity’s fixed gas detection team designed and installed a comprehensive CO₂ and O₂ detection system tailored to the cider factory’s needs. The system was carefully planned to account for the unique challenges of the brewing environment, including confined spaces such as vats, cellars, and cylinder storage areas.

Key Considerations

Carbon Dioxide (CO2):

• CO2 is colourless, odourless, and five times denser than air, which means it tends to gather in low-lying areas, forming invisible pockets that can gradually expand.
• Fermentation generates significant amounts of CO2, creating potential risks in confined spaces. Without proper monitoring, workers may unknowingly enter areas with dangerously high CO2 levels, posing a serious health risk.

Nitrogen (N2):

• While not toxic, nitrogen can displace oxygen in the atmosphere, leading to oxygen depletion—a critical hazard in the event of a gas leak.
• Nitrogen is used in several phases of brewing, such as putting bubbles into beer (particularly stouts, pale ales, and porters), preventing oxidation, transferring liquids between tanks, and pressurising kegs or barrels for storage and shipment.

Following the storage schematics above, the team strategically installed six Analox oxygen depletion sensors and six Analox carbon dioxide sensors to ensure comprehensive gas monitoring across 14 tanks.

These sensors are connected to a centralised control panel positioned outside the storage room, enabling workers to easily access real-time data and assess potential hazards before entering the area.

This setup ensures both efficiency and safety, providing a reliable system for early detection of gas-related dangers.

The Result: Improved Safety and Ongoing Support

This project highlights the importance of tailored gas detection solutions in industries beyond the obvious, showcasing Shawcity’s expertise in addressing complex safety challenges. So much so that Shawcity has installed fixed detection systems at their other locations and has enrolled the company on a service plan.

Fixed gas detection systems from Shawcity

Shawcity is one of the UK’s leading providers of fixed gas detection systems and our complete service includes site surveys, installation, commissioning and ongoing maintenance. We partner with world-leading manufacturers such as Analox, Crowcon, GDS Technologies, Honeywell, ION Science, Sensitron and Uniphos to ensure we have the most comprehensive independent offer for our customers.

For total peace of mind, we are accredited members of the Safe Contractor scheme, and all our engineers are CSCS and SSSTS certified. Shawcity is also ISO 9001:2015 and ISO 45001 certified.

Whether you’re seeking a specific solution for a new application or need support with your existing system, our team is ready to assist.

Contact the team on 01367 899419 or email solutions@shawcity.co.uk and arrange your free site survey.