Deli 24 boosts reliability with oil-free compressed air upgrade

For Deli 24, the UK's leading contract high-pressure processing (HPP) specialist, maintaining absolute confidence in its critical utilities is essential. Operating in a sector where food safety, quality and production continuity are paramount, the company has strengthened the resilience of its compressed air infrastructure at its Milton Keynes facility through the installation of a second Atlas Copco ZT22 VSD oil-free rotary tooth compressor.

Deli 24 provides HPP services for food manufacturers across a broad range of sectors, including baby food, meat, seafood, dairy and prepared meals. The process uses extremely high pressure to reduce pathogens and extend shelf life without the need for heat treatment, helping manufacturers preserve the taste, appearance and nutritional value of their products.

At the heart of the operation is a dependable compressed air supply, which supports key production functions throughout the site. From powering machinery and conveyor systems to operating air knives that dry packaging before date coding, compressed air is integral to the smooth running of the facility.

“Compressed air is an essential part of our whole process,” says Paul Winter, director at Deli 24. “From conveyor systems to the operation of key machinery, it underpins a lot of what we do day to day. When you're producing food for major retailers, everything must work exactly as it should.”

A system review
While Deli 24 had relied on an oil-free compressor for more than 15 years, supported by a long-standing service arrangement, evolving operational requirements prompted the company to take a fresh look at its compressed air system. Rather than simply replacing existing equipment, the business wanted a clearer understanding of how the entire system was performing and where improvements could be made.

Atlas Copco began the project with a comprehensive air audit that assessed not only the compressor itself but also the wider distribution network and air usage across the site. The review revealed inefficiencies, including air leaks that had previously gone undetected. As a result, Deli 24 upgraded sections of its pipework and connections using more modern systems designed to improve performance and reduce waste.

A follow-up audit confirmed the effectiveness of the improvements, ensuring that compressed air generated by the system was being utilised more efficiently throughout the facility.

“It wasn't just about replacing a machine,” Winter explains. “It was about understanding what we had, how we were using it, and where improvements could be made. That gave us a much clearer picture of what the right solution looked like.”

The audit findings also informed the next stage of the project. Alongside system optimisation work, Deli 24 installed a second ZT22 VSD oil-free compressor to create a duty/standby arrangement. The new unit operates alongside the existing compressor, providing additional capacity and enhancing operational flexibility while offering scope to support future expansion plans.

The benefits of this approach extend beyond increased capacity. By introducing redundancy into the system, Deli 24 can now undertake maintenance during normal working hours without disrupting production. Should one compressor be taken offline, the second unit is able to maintain the compressed air supply, helping to safeguard against costly interruptions.

“For us, the biggest benefit is peace of mind,” says Winter. “We've had a very reliable system over the years but having that additional compressor in place gives us confidence that we can keep running without interruption. That's particularly important in a food environment like ours.”

Air quality was another key consideration. In food manufacturing environments, especially those handling sensitive products such as baby food and ready-to-eat meals, minimising contamination risks is critical. Atlas Copco's oil-free compressor technology provides compressed air free from oil contamination, supporting applications where air may come into contact with food products or packaging and helping manufacturers maintain compliance with stringent food safety standards.

Stringent certification
Deli 24 operates under rigorous retailer specifications and certification requirements, facing regular audits from customers and regulatory bodies. Reliable access to high-quality compressed air therefore plays an important role in supporting the company's wider food safety objectives.
“As we work with a wide range of food products, including ready-to-eat and baby food, maintaining a clean and controlled environment is essential,” Winter adds. “That extends to utilities like compressed air, which form part of the overall process.”

The upgrade was delivered as a turnkey project, with Atlas Copco managing everything from planning and equipment positioning through to pipework modifications and final commissioning. Despite the limitations of an existing plant room, the system was successfully reconfigured to accommodate both compressors side by side. Additional equipment, including an air receiver, was also installed to improve system stability.

Seamless integration
To avoid disruption to production, installation work was carried out in carefully planned stages and scheduled around operational requirements. Once completed, the new compressed air system was integrated seamlessly into daily operations.

“We wanted a turnkey solution, and that's exactly what we got,” says Winter. “From the initial discussions through to installation and commissioning, everything was handled as one joined-up process. That made a big difference for our engineering team.”

Looking ahead, the upgraded compressed air infrastructure provides Deli 24 with a platform for future growth while delivering the reliability demanded by modern food production. The company is also investigating digital monitoring technologies that could provide greater visibility into system performance and enable more proactive maintenance planning.

For Atlas Copco, the project demonstrates the value of taking a holistic approach to compressed air systems.

“Understanding how compressed air is used across the site was key,” says Michelle Tripp, Oil-Free Sales Engineer at Atlas Copco. “The audit allowed us to identify inefficiencies, address them, and then specify a solution that supports both current operations and future plans. Alongside that, introducing a duty/standby arrangement gives Deli 24 the resilience and flexibility they were looking for.”

By combining system optimisation with increased redundancy and oil-free air technology, Deli 24 has strengthened a critical part of its manufacturing infrastructure. The result is a more resilient compressed air system that supports production continuity, food safety and future expansion, helping ensure that the company's HPP operations continue to run smoothly every day.