Phase 2: Fixed Gas Detection in the Drinks Industry

The drinks and beverage manufacturing sector relies heavily on fermentation, carbonation, cleaning processes, and inert gas handling. While essential for maintaining product quality and operational efficiency, these processes also create significant confined-space and asphyxiation risks, particularly from carbon dioxide (CO₂) and nitrogen (N₂).

A prominent cider manufacturer in the Midlands, producing more than 12 million litres of premium cider annually across three UK sites, recognised the need to strengthen its gas safety strategy. With large-scale fermentation operations, multiple confined spaces, and extensive use of inert gases throughout production, the business faced an increased risk of hazardous gas accumulation in key operational areas.

CO₂ generated during fermentation, combined with nitrogen used for inerting, blanketing, and pressurisation, presented potential dangers to employees working in enclosed or poorly ventilated environments. To improve worker safety and gain greater visibility of atmospheric conditions across its facilities, the award-winning cider company partnered with Shawcity to design and implement a tailored fixed gas detection solution.

Phase 1 – Initial Installation (2025)

Shawcity’s fixed gas detection team designed and installed a comprehensive CO₂ and O₂ monitoring system tailored specifically to the operational requirements of the cider production environment.

The installation was carefully planned around the unique challenges of the facility, including confined spaces such as:

• Fermentation vats
• Cellars
• Cylinder storage areas
• Enclosed processing zones.

Understanding the Risks

Carbon Dioxide (CO₂)

CO₂ is colourless, odourless, and significantly denser than air, causing it to collect in low-lying or enclosed areas where dangerous concentrations can develop unnoticed.

During fermentation, large volumes of CO₂ are naturally produced, increasing the risk of hazardous atmospheres forming in confined spaces. Without continuous monitoring, employees may unknowingly enter areas with elevated CO₂ levels, creating a serious health and safety risk.

Nitrogen (N₂)

Although nitrogen is not toxic, it can displace oxygen in the atmosphere, leading to oxygen-deficient environments in the event of a leak.

Within the cider production process, nitrogen is used for:

• Preventing oxidation
• Transferring liquids between tanks
• Pressurising kegs and barrels
• Carbonation processes across selected products

Because oxygen depletion can occur without warning signs, continuous atmospheric monitoring was essential to maintaining safe working conditions.

The Solution

Following a detailed assessment of the facility’s storage schematics and production layout, Shawcity strategically installed:

• Six Analox oxygen depletion sensors
• Six Analox carbon dioxide sensors

The system was designed to provide comprehensive monitoring coverage across 14 tanks and surrounding operational areas.

All sensors were integrated into a centralised control panel located outside the storage room, allowing employees to safely access real-time atmospheric data and assess potential hazards before entering confined spaces.

This approach provided:

• Continuous real-time gas monitoring
• Rapid warning of hazardous conditions
• Improved confined-space safety procedures
• Greater operational visibility across the site.

Phase 2 – Expansion Project (2026)

Following the success of the initial installation, the latest phase of the project is now underway, with a major expansion of the fixed gas detection infrastructure across two production sites.

At site one, Shawcity is installing:

• 44 Analox CO₂ and O₂ sensors
• 12 integrated control panels
• 13 alarm beacons

This expanded system will provide comprehensive monitoring coverage across critical production areas and confined spaces.

At site two, a further:

• 33 Analox CO₂ and O₂ sensors
• 11 integrated control panels

are being deployed to extend monitoring capabilities across additional operational zones.

Together, these systems will deliver continuous real-time gas monitoring and rapid alarm response capabilities, helping to protect personnel from hazardous gas build-up while improving site-wide safety visibility, compliance, and operational confidence.

The Result

The project demonstrates the importance of tailored gas detection solutions within the drinks industry, where invisible atmospheric hazards can pose significant risks to employee safety.

By implementing a scalable fixed gas detection strategy, the cider manufacturer has significantly improved:

• Worker protection in confined spaces
• Visibility of atmospheric conditions
• Response times to potential gas hazards
• Overall site safety management.

The success of the installation has also led to Shawcity deploying fixed detection systems at additional company locations, alongside ongoing servicing, calibration, and maintenance support through a long-term service agreement.

Through expert engineering support and purpose-built monitoring systems, Shawcity has helped the client create a safer, more controlled production environment across its operations.

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, Bacharach, Crowcon, Ion Science, GDS Technologies, MSA, Sensitron, and Uniphos to ensure we have the most comprehensive independent offer for our customers.

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.