The Brief
Foodclean was appointed as the lead supplier and single point of contact for the design, supply, and installation of a PowerBoost medium-pressure rinse system at Billington Foods’ low-risk production facility. This followed a detailed assessment of their existing washdown process, which had become inefficient, labour-intensive, and increasingly unreliable due to the limitations of their original high-pressure manifold system. With up to eight operators now needing to clean simultaneously, and growing concerns around safety, caustic handling, and cleaning effectiveness, the factory required a robust, multi-operator solution.
Foodclean’s PowerBoost System, featuring ceiling-mounted rinse stations and stainless steel pipework, was introduced to streamline cleaning, reduce chemical and water use, improve operator safety, and deliver measurable gains in both hygiene standards and production efficiency.
Foodclean WashDown Equipment & Systems
Foodclean’s Solution
To meet the demands of a growing production environment and address the limitations of the existing washdown process, Foodclean designed and delivered a tailored PowerBoost medium-pressure rinse system for Billington Foods. This solution provides high-efficiency rinsing for up to eight operators simultaneously, significantly improving cleaning performance while reducing chemical use, water consumption, and manual handling.
The PowerBoost System includes a high-efficiency, stainless steel, water-lubricated pump set, utilising two Grundfos multi-stage pumps. The unit is pressure-fed and features an automatic start/stop function with transducer-controlled speed regulation, ensuring energy-efficient operation based on demand. Mounted on a stainless steel base plate, the system supplies boosted water at 10–40 bar pressure, maintaining consistent performance across all eight rinsing points.
Ceiling-mounted rinse points were strategically installed above the cooking vessels using a fully welded stainless steel pipework system. The rinse hoses are placed within easy reach of operators, reducing setup time and enabling faster, more effective cleans. Trials confirmed that cleaning time was reduced by up to 30 minutes per cook pot, unlocking an additional 50 hours of production each week. The superior rinsing also led to a 60% reduction in caustic use for interim cleans, and an equivalent reduction in water consumption.
To further enhance safety and usability, the system includes 8x Nita SC Stainless Steel Retractable Hose Reels with Speed Control. The Nita SC system acts as a safety brake, slowing retraction in the event of accidental hose release. Each reel is supplied with a wall-mounted swivel bracket, 1.5m connection hose, colour-coded main hose, SH450 wash gun, three interchangeable nozzles (rinse, foam, sanitise), and a lockable nozzle holder.
Installation was carried out by one of Foodclean’s preferred partners, East Norfolk Pipework (ENP), with Foodclean acting as principal contractor and single point of contact. The works included placement of the PowerBoost unit in the first-floor boiler room, connection to water and power, and full installation of the stainless steel pipework system to seven cooking vessels and two hose reel stations. All water control, balancing components, and safety testing were completed in line with Foodclean’s high hygiene and engineering standards.
The result is a robust, reliable cleaning system designed for performance, efficiency, and safety – providing Billington Foods’ team with the right tools, at the right time in the right place.
Blake Wade - Technical Project Manager
‘It’s been a very successful project working with Billington Foods. They were highly satisfied with the results of the installation, noting significant improvements in cleaning efficiency, operator safety, and overall system reliability. The PowerBoost System not only streamlined their hygiene processes but also delivered measurable time and cost savings – proving to be a smart, future-ready investment for their growing production demands.’
Product range:
PowerBoost System 8x Nita SC Stainless Steel Retractable Hose Reels 2x Grundfos multi-stage pumps
Benefits:
Higher efficiency rinsing Significantly improving cleaning performance Reduced chemical & water usage Improved manual handling
Manual handling:
The Nita SC System acts as a safety brake in the event of accidental hose release by the operator. The hose reel will retract slowly reducing risk of harm to operators and damage to equipment.
Production efficiency:
The PowerBoost System is a high efficiency pump set, with controlled speed regulation, and ensuring energy-efficient operation based on demand. Supplies boosted water at 10–40 bar pressure, maintaining consistent performance across all eight rinsing points.
Sustainability:
The PowerBoost System has streamlined cleaning, reducing the amount of chemical and water use.
