Holmach, Lagarde Autoclaves, and Jorgensen Engineering have announced a significant investment of £4.5 million towards a sustainability-focused upgrade of Premier Foods’ Mr Kipling steam pudding production line. This project stands out as one of the most substantial engineering transformations in the brand’s history.
The selection of this trio was driven by their collective technical prowess, their established partnership with Premier Foods, and their capability to provide a comprehensive, integrated solution prioritizing environmentally friendly processing methods.
The investment at the Carlton bakery replaces an outdated, water-heavy retort system with a state-of-the-art, energy-efficient thermal processing line. This setup includes three static Lagarde four-basket retorts, specially designed trays, and a robotic handling system from Jorgensen tailored for the facility. Premier Foods aimed to reduce energy and water usage, move away from gas-powered steam generation, and embrace a more sustainable, electric-based processing approach from the start.
Premier Foods’ commitment to sustainability—including the development of a £2.1 million solar farm—necessitated partners who could enhance environmental performance without compromising the unique texture and quality of Mr Kipling’s distinctive dense steam puddings.
Holmach’s enduring partnership of 25 years with Premier Foods, along with its exclusive role in the UK for both Lagarde and Jorgensen, uniquely positioned it to deliver a full turnkey solution that encompasses thermal processing, automation, and line integration.
Chris Holland, managing director of Holmach, remarked: “Having collaborated with Premier Foods for over 25 years, we were thrilled to be entrusted with this technically challenging contract. Projects of this scale require unwavering confidence in your supply chain, which is precisely what such a long-standing relationship ensures.”
The innovative steam/air retort technology from Lagarde played a key role in the project. Trials conducted in the UK confirmed that this system could achieve validated sterilization with accurate temperature control, automatic F₀ calculations, and gentle handling. These factors are crucial for preserving the sponge’s integrity, moisture, and the beloved texture associated with Mr Kipling products. Moreover, the trials indicated significant reductions in both energy and water usage, in line with Premier’s environmental targets.
The new production line integrates Lagarde’s thermal processing capabilities with an entirely automated handling system from Jorgensen designed to optimize uptime and minimize manual handling. Given the instability of individual pudding pots, precision automation was essential. Jorgensen’s approach begins with robotic loading into custom trays, which are stacked neatly before being swiftly transferred to the retorts via a high-speed shuttle.
Post-processing, the trays are automatically tilted for dewatering, removed by a dedicated robot, and fed into a controlled single-file flow for packaging. This line seamlessly connects with Premier’s existing dryer and incorporates an AI-driven vision system to verify seal integrity, followed by checkweighing and X-ray inspections to ensure that every pot meets the required specifications.
Reliability is bolstered by Linefact, Jorgensen’s real-time diagnostics platform, which captures continuous sensor data, allows immediate video playback, and employs predictive AI to minimize downtime. Engineers from both companies can access real-time insights through tools like Google Glass or HoloLens, facilitating prompt remote assistance.
Sustainability is woven into every aspect of the operation. Lagarde’s direct steam injection retorts reduce steam and water usage by 30–80% compared to conventional systems, while Jorgensen’s energy-efficient motion control and robust stainless-steel construction promote long-lasting sustainability.
Collectively, Holmach, Lagarde, and Jorgensen have established a cleaner, more intelligent, and resilient production system—one that not only secures the future of Mr Kipling’s manufacturing but also diminishes the environmental impact of Britain’s cherished steam puddings.
