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Ohly, a producer of yeast extracts and yeast-based specialties, is set to enhance its production capabilities with the opening of a new spray drying tower and fermentation facility at its Hamburg, Germany, site next year.

This investment aligns with the company’s long-term commitment to sustainability and decarbonisation, as part of its affiliation with Associated British Foods.

The new fermentation plant, touted as one of the largest and most modern in Europe, aims to increase production capacity by up to 50% while significantly reducing energy and water consumption.

The facility incorporates innovative technologies, such as advanced cooling towers and automated systems, which will replace traditional 25kg packaging with larger ‘big bags’ capable of holding up to 1000kg. This shift is expected to reduce packaging waste substantially.

Rüdiger Briel, engineer and project manager at Ohly, highlighted the dual objectives of the new facility: “Our goal is to achieve the highest microbiological standards while continuously reducing our environmental impact”.

The new heat recovery system is anticipated to conserve thermal energy equivalent to the natural gas required to heat 800 homes, further underscoring Ohly’s commitment to sustainability.

The arrival of two commercial fermenters was marked by a special night-time delivery through Hamburg, illustrating the scale of the investment. The transportation required a carefully planned route to navigate the city's streets, including the iconic Reeperbahn.

In addition to environmental benefits, the new plant will adhere to the latest hygiene standards and occupational safety protocols. The implementation of automated systems aims to enhance ergonomic operation, ensuring the safety and wellbeing of employees while maintaining high product quality.

“Digitisation is key,” Briel noted, as the facility moves closer to Industry 4.0 standards through a digital control system that monitors all production processes.

Ohly’s investment also addresses supply chain security, a critical concern for food and beverage manufacturers. By enhancing its production capabilities and adopting robust supply chain management practices, Ohly aims to minimise disruptions and ensure consistent product availability.

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