Innovative Gas Detection Solution Enhances Worker Safety at AG Barr

As AG Barr continues to grow and innovate in the competitive soft drink market, maintaining both product quality and workplace safety has become increasingly important. One critical aspect of the production process involves using carbon dioxide (CO₂) for carbonation and preservation, a necessary component that also introduces safety challenges in the bottling environment.

CO₂ Safety Challenges in the Bottling Process

Carbon dioxide (CO₂) is an essential component in the creation of soft drinks, added during the production process to provide fizz. It also serves as a protective measure to extend the shelf life of the product by keeping the drinks fresh and preventing bacterial growth.

During the bottling process, CO₂ is injected into the drinks under high pressure. This allows it to dissolve and create carbonic acid, generating the small bubbles that make the drink fizzy and refreshing. While the bottles and cans are being filled, large volumes of CO₂ can be emitted into the filler room atmosphere, exceeding pre-set regulations for safe working environments.

CO₂ is colorless, odorless and tasteless, and in high concentrations can pose a significant risk to human health. Due to its hazardous nature, most countries have implemented workplace exposure limits that require the monitoring of CO₂ to avoid accumulation. Both the UK, via the HSE (UK Health and Safety Executive) and the USA, via OSHA (Occupational Safety and Health Administration) require the exposure to be less than 5,000 ppm during an eight-hour shift.

These guidelines are particularly relevant to producers of soft drinks as the use of CO₂ is integral to their process. Without having appropriate measures in place to monitor safe limits, employees are at a greater risk of exposure, leading to symptoms such as headaches, dizziness, impaired judgment, lethargy, irritation and confusion. As levels of CO₂ in the atmosphere increase, the levels of breathable oxygen in the air decrease. Inhalation of elevated CO₂ levels can increase blood acidity, triggering adverse effects on the respiratory and cardiovascular systems and posing an immediate threat to life.

Consequently, decision-makers at AG Barr required a leading-edge solution to monitor both CO₂ levels and oxygen depletion within the bottling plant to increase onsite safety and improve regulatory compliance.

A Customized Gas Detection Solution

Experts at Badger Meter, working with AG Barr, created a customized gas detection solution through the BlueEdge™ portfolio. By combining the GasSens Midi Controller with a number of gas sensors to monitor oxygen depletion and CO₂ within the atmosphere, they now have a cutting-edge system to monitor and control gas levels.

The Midi Controller is an addressable monitoring system, that provides a stand-alone measurement and logging solution for hazardous area sensing. Capable of measuring over 60 different gases or vapors and supplied with ready-to-use pre-calibrated gas sensors, the Controller has been designed to operate in a range of different environments. Featuring a large alphanumeric screen to indicate the reporting sensor, gas type, concentration and alarm status, it will automatically activate a variety of signal outputs, including analog/digital data and user-selectable relays when gas is detected, allowing pro-active management of the facility.

In addition, the D12Ex-IR Infrared Gas Transmitter uses infrared sensing technology to monitor CO₂ levels whereas the F12D Toxic Gas Detector uses advanced, hot-swappable, smart sensor technology to monitor oxygen depletion within the bottling room. Each gas sensor continually monitors the atmosphere, immediately reporting any hazardous conditions to the GasSens control unit and alerting the system operator when pre-determined safe levels are exceeded. This quickly allows the system to be safely shut down, the area to be evacuated and the doors to be locked, preventing unauthorized access and potential harmful exposure.

This tailored, specialist solution operates on a 6-core cable network and has the capacity to monitor up to 14 addressable sensors. Equipped with heated sensor holders to help with the damp location, along with splash and water guards for cleaning, the flexible system allows the client to have full control of the network. With automatic safety check diagnostics and system surveillance for complete peace of mind, it has been fully customized, through BlueEdge, to meet the individual needs of their application.

Results & Impact

For the team at AG Barr, this continuous, online gas monitoring solution provides the insights needed to maintain compliance with industry standards for safe working conditions. With this new, state-of-the-art system in place, facility managers now have the tools and data visibility needed to create a safe environment, protecting the health and well-being of site personnel while continuing to produce high-quality soft drinks for the global market.