Ohly takes big step towards decarbonisation with new facilities
Ohly will open a new spray drying tower and state-of-the-art fermentation facility at our base in Hamburg, Germany next year. We have been delivering high quality yeast extracts and yeast-based specialties from the site in Hamburg since 1836. With our investment in these new production facilities, Ohly and Associated British Foods are reaffirming a long-standing commitment to the city and making critical progress on our journey towards decarbonisation and a more sustainable future.
New fermentation tanks arrive by special night-time delivery
It was quite a sight to witness a 400-ton mobile crane and heavy load truck manoeuvring two commercial fermenters through the streets of Hamburg city centre. With such an extraordinary load, the transport had to take a special route passing by the harbour and along the famous Reeperbahn.
On arrival the fermenters were carefully lifted and guided into position in the new fermentation plant at the heart of the Ohly site.
Increased production capacity comes with reduced energy and water consumption
The new fermentation plant, thought to be one of the largest and most modern in Europe, uses the latest innovative technology to increase production capacity by up to 50% whilst simultaneously reducing specific energy consumption. The state-of-the art facility also offers great advantages in terms of reducing water consumption with more efficient cooling towers and lower levels of freshwater use. In addition, the new automated system will enable significant reductions in packaging waste by replacing the traditional 25kg bags with so-called ‘big bags’, which each carry up to 1000kg.
"Our goal is to achieve the highest microbiological standards and at the same time continuously reduce our environmental impact," says Rüdiger Briel, engineer and project manager at Ohly.
What's more, the new heat recovery system will allow Ohly to conserve and reuse thermal energy that would previously have been wasted, equivalent to the natural gas energy needed to heat 800 homes.
Improved hygiene, safety and automation
In addition to bringing energy efficiencies, the new plant will adopt the latest hygiene standards which guarantee sustainable cleaning. It also meets the highest level of occupational safety, thanks to automated systems which facilitate ergonomic operation. With a digital and automated control system, all production processes are controlled and measured bringing Ohly another step closer to Industry 4.0. "Our focus is on ensuring the safety and well-being of our employees while maintaining the highest levels of product quality – digitisation is key," emphasizes Rüdiger Briel.
Improving supply chain security
Ensuring a reliable and secure supply chain is vital to Ohly’s customer commitment. These investments in state-of-the-art fermentation and spray drying facilities, together with Ohly’s robust supply chain management practices and strategic partnerships, are designed to minimise disruptions and guarantee product availability.
These developments will further enhance Ohly’s ability to deliver exceptional products and services, strengthening their commitment to meeting their customers’ needs.