Ohly Begins Decarbonisation with New Facilities

Ohly, a global supplier of yeast specialties, is set to open a new spray drying tower and fermentation facility in Hamburg next year, marking a significant step in its decarbonisation efforts. The project, part of a broader initiative by Ohly and parent company Associated British Foods, underscores the company’s commitment to sustainability.

New Fermentation Tanks Delivered in Night-Time Operation
Two commercial fermenters were delivered to the site in Hamburg via a special night-time transport operation, involving a 400-ton mobile crane and heavy-load truck. The fermenters, part of the new state-of-the-art facility, were maneuvered through the city’s streets, passing landmarks such as the harbor and the Reeperbahn. Upon arrival, they were installed in the new plant at Ohly’s Hamburg site.

Increased Capacity with Reduced Resource Use
The new facility, one of the largest fermentation plants in Europe, is designed to increase production capacity by 50% while reducing energy and water consumption. Featuring advanced cooling systems and a more efficient water-use process, the plant aims to significantly lower its environmental impact. It also replaces traditional 25kg packaging with larger 1000kg ‘big bags,’ reducing packaging waste.

“Our goal is to achieve the highest microbiological standards while continuously lowering our environmental footprint,” said Rüdiger Briel, project manager at Ohly. The facility will also employ a heat recovery system capable of conserving enough energy to heat 800 homes.

Enhanced Safety, Hygiene, and Automation
The plant’s design prioritizes hygiene and safety, meeting stringent cleaning standards and incorporating automation for ergonomic operation. The digital control system will allow for precise management of production processes, aligning with Industry 4.0 standards.

“Our focus is on ensuring employee safety and product quality, with digitisation playing a key role,” Briel added.

Strengthening Supply Chain Resilience
The investment aims to improve supply chain security, ensuring product availability and minimizing disruptions. Ohly’s new facilities, combined with strong supply chain management and strategic partnerships, are designed to meet growing customer demand while reinforcing the company’s long-term sustainability goals.