Gressingham Foods
How Gressingham Foods cut water waste with a simple, scalable WAGO solution
– Delivered seamlessly by Parmley Graham
Overview
Water is essential to poultry production – but it’s also one of the industry’s biggest costs. For leading duck producer Gressingham Foods, understanding exactly where, when, and how water was being used proved to be the key to reducing waste, cutting costs, and strengthening sustainability efforts.
Thanks to a smart collaboration with Parmley Graham and the installation of a WAGO Energy Data Management (EDM) system, the Suffolk-based producer is now turning real-time data into real operational improvements. What began as a small pilot in the farm’s pumphouse has quickly become the blueprint for business-wide efficiency.
Business Challenge
Why the need?
From drinking systems to washing areas, heating, cooling and processing, water is central to every step of poultry production, and with every cubic metre requiring treatment chemicals, such as chlorine, the costs add up fast.
Gressingham Foods knew they needed a clearer view of their water use – not just totals, but detailed insights that could reveal leaks, inefficiencies and unnecessary waste.
The goal was simple: start small, learn fast, save money, reinvest the savings, and scale.
Solution
In late 2023, Gressingham partnered with Parmley Graham, WAGO’s specialist distributor, to design and deliver a monitoring system that would give them the visibility they needed.
Using WAGO’s Energy Data Management (EDM) solution, the team installed flow meters in the pumphouse feeding the site’s water supply. The system now provides:
Accurate, real-time monitoring of water inflow and outflow
Visual dashboards to compare usage across different production areas
Early detection of abnormal consumption — often the first sign of a leak
Reliable data to support informed, cost‑saving decisions
For Gressingham’s Engineering Manager José Almeida, the impact was immediate.
Why PG Made the Difference
José highlights PG’s role as a major reason the installation was so smooth and successful:
- Clear demonstrations that showed the system’s capabilities.
- Site surveys and technical scoping to ensure the setup was right first time.
- Hands-on commissioning and staff training
- Responsive engineering support, right when the team needed it.
He describes the entire process as “easy, proactive, and very positive.”
Beyond the support, the technology itself hit all the marks. WAGO’s open, vendor‑agnostic platform integrates with any existing meters – water, gas, electricity or air – making it a cost‑effective and highly scalable option.
Crucially, Gressingham could begin the project using operational spend rather than capital investment, reducing barriers to getting started.
Solution Impact
How has the new solution improved operations?
The Outcomes: Less Waste, Lower Costs, Stronger Compliance
With WAGO EDM in place, Gressingham Foods can now pinpoint exactly where unusual consumption is happening – right down to the specific part of the site. This means:
- Faster leak detection and repair
- Reduced treated (chlorinated) water use, cutting chemical costs
- Lower overall water bills
- Reduced risk of breaching Environment Agency borehole extraction limits
The system didn’t just deliver insights — it delivered action.
What’s Next:
Scaling Water and Energy Monitoring Across the Business
Encouraged by the success of the pumphouse project, José and his team are already planning the next phase. Their roadmap includes:
- Expanding monitoring to hatcheries and other high‑use areas
- Adding utilities like electricity and compressed air into the system
- Scaling EDM site-wide as new opportunities emerge
Thanks to the simplicity of the WAGO platform -and the confidence gained from Parmley Graham’s training and support – the team now feels equipped to extend monitoring whenever and wherever they choose.
Testimonials
"The Pepperl+Fuchs R305 sensors have transformed the safety of our conveyor systems. Previously, damaged or irregular pallets posed a serious challenge, leading to near-miss incidents that put operator safety at risk. Since installing these sensors, we have zero near-miss events and complete confidence in pallet detection. Parmley Graham’s support throughout the project was invaluable - from identifying the right technology to guiding installation, their expertise ensured a smooth, efficient process."
“Partnering with Parmley Graham and Pepperl+Fuchs has transformed our operations. The R305 sensors provide dependable, accurate detection across every pallet type, including the short, damaged, or irregular ones that used to challenge our systems. Throughout the process, the PG team’s professionalism and technical expertise gave us complete confidence. The outcome speaks for itself: a safer, more efficient conveyor system.”
“Roxane UK presented a real-world challenge where conventional sensors were falling short. By understanding Roxane UK’s challenges and leveraging Pepperl+Fuchs’ technology, we were able to specify and implement the R305 sensors, delivering a solution that immediately improved safety and reliability. Seeing the system perform flawlessly on all pallet types has been incredibly satisfying, and we’re proud to continue supporting Roxane UK on future projects."
Get in Touch
To discuss how the PG team can help, either email us at support@parmley-graham.co.uk or call 0191 478 0404.
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