A high-efficiency burner upgrade that cut costs, reduced downtime, and brought critical operations back into balance.
Overview
Baxter’s Foods, one of Australia’s leading food manufacturers, partnered with O’Brien to upgrade the burner and control system at its Campbellfield production facility. With performance and reliability concerns mounting, the goal was to deliver a more efficient, lower-maintenance solution without disrupting day-to-day operations.
We designed and implemented a complete burner upgrade and controls overhaul using an ELCO natural gas burner and our smart OBYTRON management system. The result: lower energy costs, fewer breakdowns, and a safer, more reliable system that’s now better aligned with Baxter’s operational and sustainability goals.
The Site
Baxter’s Campbellfield facility is a major production hub for the company’s chutneys and relishes, supplying customers across the country. The site’s energy systems play a critical role in ensuring consistent output — so when reliability started to slip, it became clear that a system upgrade was essential.
The Problem
The existing burner had reached the end of its useful life. It was inefficient, difficult to maintain, and prone to unplanned shutdowns. Operational costs were climbing, and production was at risk of interruption.
Baxter’s needed a long-term fix — one that would deliver reliability, reduce maintenance, and support their commitment to energy efficiency.
Our Solution
High-Efficiency Burner Upgrade
We replaced the existing burner with a high-performance ELCO natural gas model, matched specifically to the site’s 3000kW boiler. This delivered immediate improvements in combustion stability and fuel efficiency.
Smarter Controls with OBYTRON
A new OBYTRON touchscreen burner management system was installed, integrating advanced combustion controls, remote access, and real-time diagnostics. With better visibility and automation, Baxter’s team now has greater confidence in system performance.
Seamless Project Delivery
Our team managed the full upgrade from end to end — including design, installation, commissioning, and compliance. This meant fewer handovers, tighter coordination, and a more straightforward process for everyone involved.
Built for Long-Term Value
Additional features like O₂ trim, TDS control, and an economiser help reduce fuel consumption by 5–10%, while improving steam quality and minimising chemical use. The upgrade also reduced maintenance demands and improved overall system lifespan.
Results
- Energy costs cut by up to 10%
- Breakdown frequency and downtime significantly reduced
- Lower operating costs through more efficient combustion
- Enhanced safety and compliance with fully certified controls
- Smarter performance monitoring via OBYTRON remote diagnostics
- Cleaner steam and reduced emissions supporting ESG goals
These aren’t just technical wins — they’ve had a real impact on the day-to-day. Less downtime means fewer disruptions for Baxter’s production team, and a system they can trust to do its job without constant oversight.
Navigating Challenges
Like any live-site upgrade, the project involved a few unexpected factors — including last-minute gas meter delays and scope gaps inherited from earlier planning stages.
We responded by introducing a live procurement tracker tied to our bill of materials, aligning directly with Baxter’s team to re-scope where needed, and treating all remaining work transparently as variations. The commissioning phase proceeded smoothly, with no significant impact to the site’s operations.
Looking Ahead
This project reflects what we strive to bring to every engagement: a deep understanding of what matters operationally, combined with practical engineering solutions that stand the test of time.
The result was a system Baxter’s team could depend on — reliable, efficient, and built to keep production moving.
Interested in modernising your burner or boiler systems? Get in touch to see how we can help.
